Replace Stator Without Removing Engine Mod - Page 2 - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
Electrical
Where does this wire go?
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post #11 of 161 (permalink) Old 01-09-2011, 02:54 PM
Unk
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That's one of the most exciting bits of news regarding fixes for our bikes that I've seen. I bought a '93 recently and am almost ready to put it together and test it out. One of my fears (fear of a great inconvenience more than anything else) was that the stator might be worn out. I didn't get any history on the bike. If it comes down to it I'll use this method. I've already contrived a rig to hold my shop vac hose as close as possible to the work area when cutting. Metal filings was a concern and I can't help but think minimizing the intrusion would be a good idea.
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post #12 of 161 (permalink) Old 01-16-2011, 09:35 PM Thread Starter
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Quote:
Originally Posted by darrelc5 View Post
Tuxedo, good job on the stator mod.

Your sig file states that you're "Inventor of the Perfect Stator Cover Mod 11/2010." We have been discussing this for a couple of years:

https://www.vn750.com/forum/showthrea...0633#post60633

So you're the first to try it?
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Should peace break out someday, I will not claim credit for it and I will applaud those who gave it to us.

ps: Very impressive stator oil cooler system that you developed. Thank you for posting the pics and sharing it with the community.
https://www.vn750.com/forum/showthrea...ghlight=tubing
http://www.flickr.com/photos/2339973...7605602927618/
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post #13 of 161 (permalink) Old 01-18-2011, 02:13 PM Thread Starter
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Quote:
Originally Posted by Professor Tim View Post
Tux...

I'm in the middle of the process and have an interesting situation. After cutting the inside case, I'm getting a resistance like almost a spring loaded feeling and am unable to pull the stator. I've cut the the stator wires and have moved the p/u coil wires... Am I hanging up on something. The service manual shows no spring behind the stator? I've got a '01 750... HELP!!!
I'm guessing that one of the inner case ribs isn't completely severed. This thin piece of metal will give a spring effect. Get in close with a flashlight and check that out. If that isn't it, then the hole that you cut isn't wide enough and the stator is hung up. Working the small cutting wheel to the outside of the hole (reaming) will enlarge it.


Last edited by TuxedoSeven; 05-07-2013 at 01:08 PM.
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post #14 of 161 (permalink) Old 01-21-2011, 08:17 PM
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Just one major question? Where are all the dremel shavings or disc shavings?.Ya are not going to wash all those out for sure.Ya think?Inventive way of repair though.
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post #15 of 161 (permalink) Old 01-22-2011, 02:54 PM Thread Starter
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Originally Posted by Amsoil Man View Post
Just one major question? Where are all the dremel shavings or disc shavings?.Ya are not going to wash all those out for sure.Ya think?Inventive way of repair though.
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Quote:
Originally Posted by darrelc5 View Post
Most of the debris would accumulate on the inside of the flywheel drum which you could wipe out after the stator is removed. The rest - well, that's what the oil filter is for.
I stuffed oily rags into the ports before cutting. Inside I found no shavings and a minimal amount of metal dust which had accumulated in the rotor drum and was easily wiped away. I followed with an oil and filter change.
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post #16 of 161 (permalink) Old 01-25-2011, 02:56 PM Thread Starter
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Quote:
Originally Posted by Professor Tim View Post
Well, you were right about the case ribs. Got those done and out cleanly. Unfortunately, I didn't get the mounting holes right and boned my stator after my third test run. Now, I'll have to fabricate a new plate and use the wear marks on the stator to modify the mounting hole location....a drag, but still having fun. I would recommend that anyone else attempting this should do a short static test run, then pull the stator again to check for wear marks before proceeding down the road. I saw that another guy had to do four plates, so having to make a second one really isn't that bad.
Sorry for your troubles.
As stated in the slideshow: Make plate before cutting engine. Modeling clay on steel plate. Press against engine. Drill through impression with drill press.
Please do not try to freehand this.

Last edited by TuxedoSeven; 01-27-2011 at 08:05 AM.
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post #17 of 161 (permalink) Old 01-25-2011, 04:54 PM
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Originally Posted by TuxedoSeven View Post
Attachment 3306

Replace Alternator / Stator Without Removing Engine
A simple mod for my 1990 VN750 / Vulcan 750 A6 using a Dremel rotary tool and about $20- in supplies from Walmart and Home Depot can be viewed at :

http://www.youtube.com/watch?v=AN-JEBCnhDI
Simple?

I would think just cutting the frame would be alot simpler...

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post #18 of 161 (permalink) Old 01-25-2011, 08:57 PM
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Quote:
Originally Posted by Knifemaker View Post
Simple?

I would think just cutting the frame would be alot simpler...

KM
Knifemaker I read on another post that someone else thought about it and did that, and someone commented on how the frame was not designed to come apart there and it lost around 80% of the strength within the frame. Im not sure how accurate that is since i am no engineer, but it leaves that question in your head, since both downtubes would be cut and weakened, and im sure that the designers of the frame made it so that the right side piece would come out and keep its structural rigidity (check spelling). Just a thought. It would also seem it would just be a better idea to pull the engine to get to know more about your bike and how the internals of the engine fit together instead of cutting holes in factory designed engine pieces.

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post #19 of 161 (permalink) Old 01-26-2011, 12:13 PM Thread Starter
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Cutting the frame can be a safe mod if done right. Check out the Gallery:

https://www.vn750.com/photopost/showp...24&ppuser=1321

The side cover stator mod would be a good idea even during an engine removal. Stators go bad, sometimes right after an engine removal. I'm a big fan of 10 minute repairs.
God Bless You and stay safe.

Last edited by TuxedoSeven; 03-19-2011 at 06:37 PM.
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post #20 of 161 (permalink) Old 01-26-2011, 02:04 PM
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I have no problem changing things and doing some mods, all im saying is i personally wouldnt cut the frame down tube or the engine cover, buts just my personal preference. I have nothing against your mod, it seems like it would work great, but some mods are just not for some people.

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1986 Vulcan 750, paid in full (250 bucks)

R/R Relocated (Thanks flitecontrol)
Splines Lubed
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Planned mods and things:
Ear shave (using stock ears as storage)
Coastering
Wrapping exhaust
Custom Exhaust
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