Wow, that sucks. ('81 GS 550)

[SuperCell]

Just got my Haynes manual in the mail, and it does not outline replacing the stator. Unbelievable. They show you how to pull the engine and tear it down, but they wont show you how to replace the stator!

I'm pretty sure I can handle it as I'm a full-time auto-tech. It's just that I've never done this type of repair before, and I need some help.

Any information would be greatly appreciated.

[ddaum]

From my manual:
Clymer M373 for Suzuki GS550 1977-1986

Alternator Stator
Removal/Installation

1. Drain engine oil.
2. Remove the bolts securing the starter motor cover and remove the cover.
3.Remove the seat or side covers and disconnect the alternator wires.
4. Loosen the fasteners securing the alternator cover.
5. Remove the fasteners, cover and gasket. Note the location of the different length fasteners. Keep a few rags handy, as some oil is bound to run out when the cover is removed. Note how the alternator wires are routed through the cover and crankcase.

CAUTION
Do not pry the cover loose with a screwdriver or the cover or the crankcase sealing surfaces will be damaged. The cover is held tight by the magnetic attraction of the alternator rotor. A strong pull is required to overcome the magnetic force.

6. Remove the screws securing to stator assembly and wire retaining clips to the alternator case and remove the stator assembly. Note how the wiring is routed.
7. Installation is reverse of these steps. Keep the following points in mind:
a. Make sure the alternator wires are correctly routed in the alternator cover and the grommet is installed in the notch.
b. Install a new cover gasket and route the alternator wires into the crankcase opening. Hold the gasket in place and install the alternator cover.
c. Connect the alternator wires and install the starter motor cover.

It should be pretty straight forward. take your time when trying to remove the cover so you don't damage the sealing surface. Don't forget to add oil after the work is done and before starting the engine to test.

PS - Try looking in your manual under "Electrical System", if not there, look under "Engine".

[SuperCell]

Thanks a lot. I really appreciate you doing that.

Thanks

[Guest]

Attach jumper cables to battery, other ends to stator cover Oh wait, just kidding:-)

[ddaum]

Thanks a lot. I really appreciate you doing that.

Thanks

No problem, thats what we're here for