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Join Date: Nov 2007
Location: Chandler, Arizona
The original stator in my 2002 model lasted past 70,000 miles. I just bought a 1997 with 21,000 on it. Right now the stator is working great. But it could die at any time. In my current condition I don't know if I would try to replace it or not. If I were in good health, I would take the rewound one out of the 2002 and use it. I might just cut the frame to get it out of the bike. I put considerable thought in just pulling the engine out of the '97 and putting it in the '02, but that is more work than I can handle now. I found the splines good on the '97, and that gives me hope that everything else is ok as well.
When I had a 1985 Goldwing, someone figured out how to mount a Suzuki car alternator on the outside of the engine, and install a pulley on the front of the crankshaft. The 1984-1987 Goldwings were also known for stator failures, and you had to pull the engine to replace one. The alternator setup solved a lot of problems. It was easy to replace if it failed, and it did not need a RR. That was part of the alternator. It put out a lot more power than a typical motorcycle stator. But the biggest advantage to having a true alternator (like the 1988 and up Goldwings have) is that the output is controlled by the load. On a typical motorcycle stator/RR setup, the stator puts out full power at all times, and the RR takes any unused current and literally shorts it to ground. That makes them get hot, which is why they have a heat sink. About the dumbest idea I've ever heard of, but almost all motorcycles use it. I believe I saw a picture of a Vulcan 750 with an externally mounted alternator somewhere. Done right, that could be a permanent solution to the stator issue.
I am a motorcyclist, NOT a biker.
1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike