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ViragoTechForum.com General Help Changing Your Stator

#1:  Changing Your Stator Author: mark75 Post Posted: Sat Apr 21, 2007 3:31 am

Ok, my battery keeps running down and I have to recharge it every night. I put the meter on the battery and it says 12.46 volts, I start her up and it reads 11.83 volts. Hmmm,,, check the regulator and it's fine, check the 3 white wires and sure enough, direct short. MY STATOR IS SHOT!
Now what do I do?
No worries, it's an easy job, you could almost do it on your lunch break, but you should wait until you get home.

First, go to your favorite parts supplier and order one, or if you are a hard core bargain hunter/gambler, and not in a hurry, you can hunt one up on eBay(new or used).
In the mean time, get the other things you will need together:

Basic tools,
5mm allen head wrench,
10mm, 14mm, 17mm wrenches and/or sockets,
torque wrench,
new gasket,
gasket sealer,
gasket scrapper or equivalent,
manual,
clean rags,
3 quarts of oil(you will have to drain the old),
Torx head tool, not sure of designation it's 5mm, Craftsman #T30 ?, but you might be able to use a screwdriver,
blue LocTite,
thin metal ruler or stiff plastic one,
marker(any color),
a piece of cardboard(9 x 11 or so),
and any comfort items you might want, chips, cold refreshment, Prozac.

UPS finally brought your new stator, so put your baby on her center stand and drain the oil.

Remove the left side cover and tool box, crash bars(if you have them), and the left peg bracket. Mark the shifter and shaft for easier reassembly alignment and remove it.

Remove the left cover bolts in a crisscross pattern and stick them into the cardboard that you have drawn the outline of the case, in the corresponding spot. When you remove the cover of the clutch adjuster(there's a bolt under there too), you will have to take all the tension out of the clutch cable and disconnect the cable from the clutch lever arm(there is a metal tang that holds the end of the cable in it). Pull the cable out of the case and move it out of the way.

Remove the solenoid lever cover, and the 2 screws that hold the solenoid cover on. This is where the Torx comes in, the left end is a collar the lever is in, that takes the Torx, remove that, also there is a bolt underneath in the middle of the lever that acts as a fulcrum, remove that. The lever will now swing out and detach from the solenoid. The TORX collar and the fulcrum bolt get the LocTite when reassembling.

The left cover is now free to come off, but do so gently, as there is a spiral starter gear that may want to come off with the cover, but that needs to stay put. As you pull the cover off, make sure it doesn't come off the shaft(there is a spring holding it to the #1 idler gear)*more about this later*.

With all the wires disconnected, you now have the cover off and the stator exposed, note the position of the wires coming off of it, you want to install the new one in the same position or the wires wont fit. Note there is a bracket holding the wires down and away from the rotor. It has one of those crummy Phillipp's screws, I had to remove it with vise-grips, and replaced it with an allen head bolt. When you remove the old stator, you will notice it has spacer that must go on the new one, notice the alignment of the notch for the wires.(see pic)

Make sure all gasket surfaces are clean, apply gasket sealer per product instructions, then reassemble in reverse order.

* When you are putting the cover back on (remember the gear with a spring?) push it in towards the engine and hold it there with the ruler as you push the cover on. It's the only way to get things lined up and the cover to go on.

Tighten in crisscross pattern. Torque to 5.8 ft/lbs

Don't forget to connect the neutral switch wire, it's the one with the "buck horn" connector.

Your Haynes says all this in about 1 paragraph, but I had fun, and I hope this helps. I did this on an '86 - 700, but it's probably about the same for all the V-twins. '81-'83 wont have the starter lever to deal with.



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#2:   Author: Aussiexv1100 Post Posted: Sat Apr 21, 2007 3:51 am

Thanks for that walkthrough mark, well done, maybe a contender for a place in the KB section.

Just hope I never need to use it.
Aussie

#3:  Re: Changing Your Stator Author: yamaguzzi Post Posted: Sat Apr 21, 2007 7:23 am

thanks again mark, a lot of trouble you go through, , appreciate it, yamaguzzi

#4:   Author: rogsatt34 Post Posted: Sat Apr 21, 2007 11:00 pm

I recently performed this task. I wish this had been there for me. It would have saved me a lot of guess work.

#5:   Author: mark75 Post Posted: Sun Apr 22, 2007 12:55 am

Thanks guys, I appreciate the feed back.
Next up, turning a beat-up old double seat into a single for your bobber.

#6:  Re: Changing Your Stator Author: grazingazer Post Posted: Sun Apr 22, 2007 8:38 pm

can't wait for that seat mod walk thru BurnOut

#7:   Author: mark75 Post Posted: Mon Apr 23, 2007 3:04 am

Look in my album and you can see what I'm starting with.
gonna take a little longer than I planned, screwed up my finger this week-end and will have to let that get better first. doh
ViragoTechForum.com General Help Changing Your Stator


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