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450 Electrosport stator

  • Thread starter Thread starter davidduarte
  • Start date Start date
just ordered a new stator today; let's hope it doesn't take more than a week to get here from California. Of course, I'm also waiting on the gasket for that case as well.
 
I now have the gasket, so tonight when I got home, I took the impact driver and loosened all the philips head screws holding the case on. I'm glad that went smoothly, as when I did it on the 850, I ended up having to drill one screw and remove it with an extractor. I'm working a day shift tomorrow, so I'm hoping to tear the case off and replace the stator after dinner, and with any luck I'll have some better voltage readings soon! :D
 
Looking forward to how it goes! I did a few screw heads in on mine pulling it off all those many years ago, so this time I got the Z1 SS allen head kit and some anti seize to try and avoid it in future.
 
pete said:
Looking forward to how it goes! I did a few screw heads in on mine pulling it off all those many years ago, so this time I got the Z1 SS allen head kit and some anti seize to try and avoid it in future.
Click to expand...

left side engine case off. Fun little things that the manual doesn't tell you: in addition to the 8 screws holding said case on that you can see, there are two more that are hidden behind the sprocket cover :S nice thing is that they are all the same size and length. Removed the old stator, got the new stator in place. It's been a long time since I've done this; how anal do I have to get about getting the surfaces clean for the new gasket? I got the old gasket off pretty easily. It only broke in one place, and didn't appear to get stuck or leave much if any residue either on the case or the engine.
 
Man I shoulda remembered that! Yes there are an extra pair behind there... sheesh...

I was pretty anal with old gasket material on mine, and if I recall correctly there needs to be a bit of sealant under there as well, don't have a manual here at work to confirm though...
 
I've done just about all I can do tonight. Tomorrow I'm going to the hardware store to get stainless steel allen head cap screws to replace the philips head screws that hold the case in. I think I will also scan a copy of the gasket and post it in the forums somewhere. If it ever gets discontinued, then making a new one will be a cinch.
 
I would put a small amount of sealer around where the wires go thru.. Gasket doesn't need any BUT the surfaces need to be clean. DID your stator look burnt ? 50 VAC is low? but if they are all the same ? Make sure the reg is grounded good to the battery. Take a reading battery + TO fuse block + difference should be less than .5 volts
 
Last edited:
SqDancerLynn1 said:
I would put a small amount of sealer around where the wires go thru.. Gasket doesn't need any BUT the surfaces need to be clean. DID your stator look burnt ? 50 VAC is low? but if they are all the same ? Make sure the reg is grounded good to the battery. Take a reading battery + TO fuse block + difference should be less than .5 volts
Click to expand...

450 doesn't have a fuse block, just a main fuse, but I'll check that out. I've been meaning to replace some of the wires in there anyway; now would probably be a good time to do it :) The surfaces are in good shape, I need to get some Scotch-Brite and just lightly clean it up.
 
here's the old stator along with the new one:

2011-07-19_21-38-16_581.jpg

2011-07-19_21-37-19_603.jpg


unlike the 850, all the screws are the same length:

2011-07-19_21-35-43_427.jpg


They are 6mm x 35 mm, which is somewhat of an oddball size, at least my local hardware store didn't have them. I got hex head screws instead, but I may order these:

http://monsterfastener.com/itemview.aspx?itm=SCSBSS-168

They look more like the original philips head screws, but much easier to get out :)
 
well, it's all back together now. I used some RTV for the grommet, but it will have plenty of time to cure, as my wife and I are headed to Maine tomorrow for a few days. Now I'm just hoping and praying that everything is copacetic and doesn't leak or otherwise malfunction, as I've been at it for about 2 hours tonight and my back is killing me. Actually, it was less than that, because part of that time I also changed the oil in my car. I'll let you know how it goes when I get back.
 
Nice one David, and good idea on scanning the gasket!

Hope you have a nice few days and looking forward to seeing how it goes when you get back.

My wife and I would love to visit Maine one day... not sure if it'll happen or not though as I'm not sure if we could stomach the flight...
 
I forgot to mention that as I sat down to secure the case cover, I realized that the hex head screws would not work, as the holes are somewhat recessed, so I ended up re-using the old philips head screws. I like the button head cap screws better than the socket head screws, as the socket heads have a higher profile. The button heads are very similar in profile to the original philips screws. This isn't as important on the 8 screws that are immediately visible on the outside of the case, but I'm concerned about clearance problems with the 2 screws behind the sprocket cover. With a socket head, I'm not sure I'd be able to get the sprocket cover back on. Pete, did you have any trouble in that area?
 
No troubles at all David, everything went in easy and I had no clearance issues anywhere at all. The two in the signal generator area on the right side case cover were fine too.
 
Eureka! I had put the new stator in, put some RTV on the grommet where the wires came through the case, socked all the screws back in, and left it over the weekend. Came home and...still not getting great voltage at the battery. Today I went to Advance Auto Parts and got a mini-fuse holder and some 15 amp fuses, along with some ring terminals. I replaced the old fuse holder, put in all new bullet connectors, and also extended the black wire from the R/R to the grounding wire from the negative terminal on the battery. I also replaced said grounding wire. Fired it up, and finally got 14 + volts at 4000 rpm :)
 
Excellent news David! So you had two problems? The toasted stator and the dodgy connectors and fuse holder?
 
pete said:
Excellent news David! So you had two problems? The toasted stator and the dodgy connectors and fuse holder?
Click to expand...

I'll have to post pictures later on after I get home, but yes, some of the wiring was more or less buggered. The new wire I used was 12 gauge, so I'm sure that has made a difference as well. Good to give the electrons a bit bigger pipe to flow through :) I want to do the coil relay mod on this bike, but I'm not quite sure where to start. I have seen some of the threads on this mod, but haven't really had time to fully digest any of them.
 
If you do the cleanup right, you shouldn't need the coil relay mod. I've gotten my voltage drop down from around 2v to 0.2 - 0.5v by cleaning everything up, including the guts of the ignition and kill switches which appeared to cause the most grief.

After doing that work, the coil voltage is generally just over 12v which I'm happy with.

I've yet to test my charging system fully, so that's all just with a car battery attached for the moment.
 
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