Replace Stator Without Removing Engine Mod - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 161 (permalink) Old 12-19-2010, 07:02 PM Thread Starter
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Lightbulb Replace Stator Without Removing Engine Mod

Fresh links:

youtube:
http://youtu.be/Dcw-RP3Tr48

OFF BIKE Stator Cover Mod:
https://www.facebook.com/media/set/?...1&l=97324c288a

facebook:
http://www.facebook.com/pages/90-Kaw...27574493969109

Last edited by TuxedoSeven; 05-02-2013 at 07:52 PM.
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post #2 of 161 (permalink) Old 12-19-2010, 07:14 PM
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Quote:
Originally Posted by TuxedoSeven View Post
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

16 gauge 12" x 12" steel plate / Home Depot / $10.
3(6mm x 15mm) + 3(6mm x 25mm) machine screws / Home Depot / $4.
High Temp silicon / Walmart /$4.

Use a compass to measure and make perfect circles.
Use modeling clay(play doh) to transfer hole locations to steel plate for drilling.
This is cool ,but not for the inept or faint of heart.That being said I'd tackle it if faced with a stator failure. Good job!




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post #3 of 161 (permalink) Old 12-20-2010, 12:38 AM
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I would like to order your ready made kit complete with plate etc. How much?

2011 Suzuki VSTROM DL650 with ABS Purchased Jan 28 now with 39,000miles WRECKED JAN 12 ,2013
"To strive, to seek, to find, not to yield."
05 Vulcan 750 26,050miles *Traded in*
Ventura guards
MadStadt mount
Givi windshield/Heated grips
Backoff
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Givi 52 topcase
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post #4 of 161 (permalink) Old 01-07-2011, 03:21 PM
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I am interested in tools that are used to open holes and what is the diameter of the hole and that the thickness of sheet metal?
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post #5 of 161 (permalink) Old 01-07-2011, 10:23 PM
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Quote:
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

16 gauge 12" x 12" steel plate / Home Depot / $10.
3(6mm x 15mm) + 3(6mm x 25mm) machine screws / Home Depot / $4.
High Temp silicon / Walmart /$4.

Use a compass to measure and make perfect circles.Use modeling clay(play doh) to transfer hole locations to steel plate for drilling.
Quote:
Originally Posted by Milan View Post
I am interested in tools that are used to open holes and what is the diameter of the hole and that the thickness of sheet metal?
Use a compass or tape measure to measure the outside diameter of the bolt heads pattern on the outside of the stator cover to get a good estimate of diameter of the steel holding plate needed once you get inside. (See youtube video). TuxedoSeven bought a 12"X12" piece of 16 gauge, but I bet you can get at least 4 discs out of a piece that big. Can`t get to my bike right now to measure myself.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/11-vn750-general-discussion/9127-top-ten-items-you-would-suggest-new-owner-do-his-new-ride.html
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post #6 of 161 (permalink) Old 01-08-2011, 02:10 AM Thread Starter
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Fresh links:

youtube:
http://youtu.be/Dcw-RP3Tr48

OFF BIKE Stator Cover Mod:
https://www.facebook.com/media/set/?...1&l=97324c288a

facebook:
http://www.facebook.com/pages/90-Kaw...27574493969109

Last edited by TuxedoSeven; 05-02-2013 at 07:53 PM.
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post #7 of 161 (permalink) Old 01-08-2011, 08:32 AM
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Brilliant!

Scheherazade
'86 VN750
MF Battery, Iridium Plugs, RR relocated, Voltmeter, 170/80/15 Kenda Kruz rear tire, DIY Samsonite hard bags, DIY shaved seat with Beaded seat pad ('cause that's how I roll) and the dreaded STATOR CHANGE.

Shining Black Bess '86 VN750, retired for parts after a fried stator and being knocked (kee-runch) in her parking spot.
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post #8 of 161 (permalink) Old 01-08-2011, 02:25 PM
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Quote:
Originally Posted by TuxedoSeven View Post
My plate is 5 1/4" across (circle with 2 5/8" radius)**. I used 16 gauge because that's what they had at my store. Heavier gauge would be fine and would only require a thicker gasket and longer screws.

Holes are 6mm (to accommodate 6mm machine screws) made with drill press through clay impression.

I'm a little concerned that we might be overthinking this because at no point during modification did I need to know what the exact dimensions of the plate were. Best to measure everything with a compass from the center of the rotor bolt so that the results are good circles of correct size.

It really is as simple as the slideshow makes it out to be.
Thanks for the measurement TS. I realize this conversion is not rocket science, and the Youtube pictures do a good job of explaining the procedure. That 5 1/4" diameter of the plate is what I wanted to estimate, to be sure I had piece in my junk drawer that was big enough before dismantling the stator case. Maybe you can add this dimension to the youtube details like you did with the 16 gauge spec.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/showthread.php?t=9127
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post #9 of 161 (permalink) Old 01-09-2011, 12:01 PM
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Quote:
Originally Posted by TuxedoSeven View Post
It really is as simple as the slideshow makes it out to be.
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?

Darrel
'03 Vulcan 750 (90k miles)
-Corbin Seat
-V-Force Windshield
-LeatherLyke Touring Bags
-Chrome Luggage Rack
-Headlight Modulator
-Brakelight Flasher
-MF Battery
-Heads-Up Voltage Monitor
-Replaced Stator (9,000 and 16,000 mi.)
-Oil-cooled Stator Mod (photos)
-Replaced and Relocated R/R
-Greased rear splines
-Fused Stator (photos)
-Metzeler ME880 Marathon 170/80-15 (Rear), 110/90-19 (Front)
-TOC MCCTs installed
-Headlight Relays
SOLD - 2013
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post #10 of 161 (permalink) Old 01-09-2011, 01:39 PM
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You guys are F'n sharp! When my stator goes, am I gonna try this mod ?
... you betcha!

I think I will use a milling bit for cleaning up the cut of the engine casting, and I will have a tool and Die shop make the plate to exact dimensions.

I do have some concern that I might get metal filings in the engine. I'll just protect as best as possible, and maybe do an oil & filter change afterward.

~~C8> Ratt
________________________
'91 VN750 - Cosmic Splendor/Candy Wine - 10k mi.
Done: Coastered, .020 ign., Iridiums, VM, Plexistar II, MCCT's
Next: LED's
Will Do: MOSFET, Horns, Shave(maybe)

Last edited by ZCraggRatt; 01-09-2011 at 01:45 PM.
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