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How to replace your stator - A pictoral guide

  • Thread starter Thread starter BassCliff
  • Start date Start date
B

BassCliff

Guest
Greetings everyone,

Yes, it was an eventful weekend but I still found time on Sunday to replace my stator while I was changing the oil. Or did I change the oil while I was replacing my stator? Anyway, after replacing the r/r (Thanks to Mr. duaneage for the Honda r/r!) and still having a charging problem, knowing I had a good battery, left only a suspect stator. Here's what I found when I removed the left crankcase cover:

DSCF2495_oldstator.jpg


As you can see, a few of the coils had damaged insulation. Two of the damaged coils are on the same leg of the stator (this being a three phase, 18 pole, AC generator with 6 coils per leg spaced evenly around the part). In effect, these damaged coils were just lumps of copper resistance and were no longer coils that produce alternating current. It's no wonder my bike wasn't charging.

Here is the new part I got from RMSTATOR installed in the cover and ready for reassembly. They also have an ebay store that usually sells this part for $10 less and includes free shipping. I paid $101 total for the part ($2 for insurance).

DSCF2513.jpg


I also replaced all the bullet connectors between the r/r and stator. Here is a picture of what I had when I began the procedure.

DSCF2492.jpg


And here is a picture of the final wiring with the new insulated blade connectors all dressed and neat.

DSCF2525_cleanconnections.jpg


Now my bike is charging properly, all the lights are brighter, and I think it's even running a little better because it's getting full voltage to the spark plugs.

For a complete pictorial guide of my stator replacement experience, please visit the BikeCliff website. There you will find my stator replacement procedure in PDF format for your downloading pleasure. Please let me know what you think. I hope someone might find it useful.

Thank you for your indulgence,

BassCliff
 
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Good job! Thanks for sharing with pics and everything! I used the same connections for my stator and R/R execpt I don't have that bulky airbox in my way.;-)

That old stator is FRIED!!! I bet your best friend was a battery charger.
 
chef1366 said:
Good job! Thanks for sharing with pics and everything! I used the same connections for my stator and R/R execpt I don't have that bulky airbox in my way.;-)

That old stator is FRIED!!! I bet your best friend was a battery charger.
Click to expand...

Hey, thanks Bill...uh, I mean Mr. chef1366. Yes, my "Jessie" would get a trickle charge every night. And what's the matter with her airbox anyway? I think she's got a nice airbox and it gets the job done for me. :wink:

Thank you for your indulgence,

BassCliff
 
Single unit r/r

Single unit r/r

Hi Mr. s0crates82,

Here is a picture of my old r/r (left) and the Honda r/r "upgrade" on the right.

DSCF2458.jpg


Mr. duaneage, of this forum, usually has a few available. As you can see, it's a beefier unit than the stock part.

Thank you for your indulgence,

BassCliff
 
the slim one looks like the one i just got from z1enterprises to replace my fried oem rectifier. i've got a 78' gs550e.

http://www.z1enterprises.com/detail.aspx?ID=1920

Fits Suzuki GS250T (78-82) GS400 (77-78) GS425 GS450E (80-83) GS450L (80-82) GS450S (80-82) GS450T (81-82) GS550E (77-80) GS550L (80-83) GS550M (82) GS550T (80-82) GS650E GS750L (79-82) GS750T (82) GS850G (79-81) GS850GL (80-81) GS850L (80-82) GS1000 (78-80) GS1000E (78-80) GS1000G (80-81) GS1000GL (80-81) GS1000L (79) GS1000S (79-80) GS1100E (80-81) GS1100G (80-81) GS1100GK (82)
Click to expand...
 
Mr. s0crates82,

That part will work OK. It's just not "heavy duty" and has less surface cooling area. These parts can get hot. Mr. duaneage usually has the Honda parts, he even puts the regular bullet connectors on, for around $40.

We'll see in a few thousand miles how well my new electrical components hold up. So far, so good - but I've only ridden about 500 miles since the new r/r and 35 miles since the new stator. I'll keep you informed.

Thank you for your indulgence,

BassCliff
 
Great Job Cliff, everything Looked Familiar as Bwringer did the same job on My bike back in September except My RR tested OK. Ride On!
 
Nice work once again Cliff. :)

Your next assignment: post a pictorial on Rewinding A Stator. 8-[

I've got a spare with burn spots just like yours. Going to have a go at rewinding it some day - just lacking a pictorial from someone like you to lead me through it. [-o<
 
Nessism said:
Nice work once again Cliff. :)

Your next assignment: post a pictorial on Rewinding A Stator. 8-[

I've got a spare with burn spots just like yours. Going to have a go at rewinding it some day - just lacking a pictorial from someone like you to lead me through it. [-o<
Click to expand...
There was one posted on this site not too long ago. Do a search. :-D
 
Your humble servant

Your humble servant

Hi folks!

In this site's very own Stator Papers is a "How to rewind your own stator" page. I'm afraid I've done a bad thing and already tossed my old stator. The trash man picked it up this morning. Sorry Mr. Nessism, it may be a while before I can create a pictorial guide. 8-[


Thank you for your indulgence,

BassCliff
 
Very good of you to take the time to share.:)
I looked at your website info and if you don't mind, I'd like to add a couple little thoughts. I just replaced my stator and starter clutch too.
I suggest using dielectric grease to all electrical connections. Very good stuff.
Also, if you have some old, LONGER Phillips screws around or whatever (I did because I've changed all the Phillips to Allens) that have the same thread as the ones for the stator case, just cut the heads off 2 of them, turn them in a few turns at opposite ends of the case, and now you have guides to allow you to easily install the cover without it fighting you. Just slip the cover over both guide screws ends and it just about installs itself.
 
Your humble servant

Your humble servant

KEITH KRAUSE said:
Very good of you to take the time to share.:)
I looked at your website info and if you don't mind, I'd like to add a couple little thoughts. I just replaced my stator and starter clutch too.
I suggest using dielectric grease to all electrical connections. Very good stuff.
Also, if you have some old, LONGER Phillips screws around or whatever (I did because I've changed all the Phillips to Allens) that have the same thread as the ones for the stator case, just cut the heads off 2 of them, turn them in a few turns at opposite ends of the case, and now you have guides to allow you to easily install the cover without it fighting you. Just slip the cover over both guide screws ends and it just about installs itself.
Click to expand...

Mr. KEITH KRAUSE,

I love the tip about using old headless screws as guides for replacing the stator cover. And I'm sorry about not mentioning dielectric grease. You're right, it's good stuff and keeps the connections from corroding. Thank you for sharing your expertise!

I hope the fires are not too close to you. Let's all keep the victims and the firefighters in our prayers.

Thank you for your indulgence,

BassCliff
 
Your humble servant

Your humble servant

Hello friends,

I just wanted to let you know that, for your convenience, I have resized and resampled all of the PDF files on my little BikeCliff website. They still look good but the file sizes are smaller for quicker downloading. The largest file is only 1.5MB.

Thank you for your indulgence,

BassCliff
 
BassCliff said:
I hope the fires are not too close to you. Let's all keep the victims and the firefighters in our prayers.
Click to expand...
I'm not near the fires. Closest one is a good 20 miles away.
Many others lost their homes though. San Diego is like a war zone. So sad to see peoples dreams wiped out. A few have died I understand.
And to think that much of it was caused by an arsonist. I can't understand why people like that were ever born.
 
Pictorial guide updates

Pictorial guide updates

Mr. KEITH KRAUSE,

Glad to hear that you are not near the fires.

I just wanted to let you know that I have edited the text of my little stator replacement tutorial and added your wisdom to it. Thanks again for your suggestions.

I have also edited the valve adjustment and oil change tutorials with suggestions from Mr. Steve and Mr. salty_monk, and lightened up and resized pictures to make them easier to see and improved the layout. Thanks to you two for your keen eye and expertise.

Thank you for your indulgence,

BassCliff
 
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