• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Wow, that sucks. ('81 GS 550)

  • Thread starter Thread starter SuperCell
  • Start date Start date
S

SuperCell

Guest
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.
 
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".
 
Last edited:
Attach jumper cables to battery, other ends to stator cover Oh wait, just kidding:-)
 
You must log in or register to reply here.
Back
Top