Stator is Off - Questions

[cowboyup3371]

So, I finally got the stator off after about two trips to town for tools that didn't work very well. But it's off and here's what it's looking like:



So based on what what I saw of Basscliff's pictures I would say this thing is shot?!

But, in the process of taking it off, one of the washers fell out. Does it go here?



Also, should I realign these gears when I stick the cover back on?



Thanks. Off to the junk yard to see if I can get a new one.

[posplayr]

looks about normal .........





























for a fried stator

[Buffalo Bill]

Learner's permit…

“Off to the store for tools…”
Well you're on the right track and you got a good text book, but you got to do your own class work Bro, and pay your own tuition.
Best O' luck!
Bill

[BassCliff]

Hi,

Wow, that stator looks charbroiled.

http://www.alpha-sports.com/suzuki_parts.htm?fpg=/spst/1981%20GS550T/09.htm

I'm not seeing a washer in the area, except for #31 for the starter cover.




Oh, wait. This just in...

http://www.alpha-sports.com/suzuki_parts.htm?fpg=/spst/1981%20GS550T/47.htm

You may be correct with the washer placement (#3). Have a look at the starter clutch fiche.





Thank you for your indulgence,

BassCliff

[cowboyup3371]

Thanks Basscliff. The one that fell out looks like it's number 3 on the inside closest to the casing. I appreciate it.

[Steve]

Thanks Basscliff. The one that fell out looks like it's number 3 on the inside closest to the casing. I appreciate it.

You should have TWO of those washers, one goes on the inside, the other on the outside of the gearset.

.

[Big T]

1. That's one dead, dead stator
2. You should realign those gears before putting the cover on
3. As stated, there's a washer on both sides of the cluster gear

You should really think about a Rick's stator. A used on will probably put you back to where you are now. And stop by your Ace hardware with the cover and get some (stainless) allen bolts to replace those crappy Phillips screws

It sounds like you don't have an impact driver. I strongly urge you to get one for side cover bolts and those 3 stator bolts

[cowboyup3371]

1. That's one dead, dead stator
2. You should realign those gears before putting the cover on
3. As stated, there's a washer on both sides of the cluster gear

You should really think about a Rick's stator. A used on will probably put you back to where you are now. And stop by your Ace hardware with the cover and get some (stainless) allen bolts to replace those crappy Phillips screws

It sounds like you don't have an impact driver. I strongly urge you to get one for side cover bolts and those 3 stator bolts

Sad part was Big T I did pick up a cheap impact driver from HF last night and it only knocked out three of the cover screws and all of the inside ones; stripped the heads on the rest. I had to use my dremel to cut slots and then finally use the screwdriver like a chisel to force each one to turn. Both the screws and the cover have alot of corrosion on them. I already picked up allen bolts from my local motorcycle shop to replace them.

Steve and Big T, one washer stayed in the cover while one fell out when I took the cover off. I think someone didn't do something right before for the other one to fall out like it did. I'm sure glad that Basscliff found that schematic for me (I didn't bother to think to look at one myself) so I know how to put it back together correctly. Especially since the Clymers manual I checked out from the library doesn't even say anything about it.

I'll look at the gears tomorrow to find any special markings on them for realignment. Hopefully it won't be too difficult.

[Buffalo Bill]

Be gentle with aluminum…

Well silly me, I always seem to get those screws out with a screw driver. Just some knocks with a hammer and a nail set to break them loose, then some muscle carefully applied and they pop loose.
When you tighten those cover bolts during reassembly, be careful and use a torque wrench if you have one. The aluminum threads can only handle a few foot pounds before they strip. I mean like only 1 or 2 foot pounds.
You can break or strip just about every bolt known to man if you try. I done my share, now I take care.
Bill

[Nessism]

The stock phillips head screws are similar to a #3 bit and there is no way in heck to get them out many times without an impact. Regarding tightening them back in place, the spec is in the range of 50 in-lbs which is about 4 ft-lbs. Stainless steel kits are available from places like Z1 Enterprises and are highly recommended.

[koolaid_kid]

looks about normal .........

for a fried stator

That was helpful.
You can also purchase SS allen screws in bulk from McMasters-Carr, I did it for my carb rebuild and it was close to the price for single screws from Ace Hardware. But Ace is the place (that should be a jingle) to find individual screws. Getting the phillips head screws out should be a one time event, always replace them. They actually use a Japanese size bit, which is why our American screwdrivers have a difficult time with them.
The kits replace the external screws such as the stator cover to the engine, but will not include the ones that attach the stator to the cover.

[posplayr]

The stock phillips head screws are similar to a #3 bit and there is no way in heck to get them out many times without an impact. Regarding tightening them back in place, the spec is in the range of 50 in-lbs which is about 4 ft-lbs. Stainless steel kits are available from places like Z1 Enterprises and are highly recommended.

I use a rachet driver with #2 (IIIR) with plenty of pressure and can usually extract 90-95% without using an impact. A light rap to seat the bit into the screw head helps.

[posplayr]

That was helpful.

Just offering an expert opinion on the fact that there was nothing unusal.

[Buffalo Bill]

Lesson learned…

I use a rachet driver with #2 (IIIR) with plenty of pressure and can usually extract 90-95% without using an impact. A light rap to seat the bit into the screw head helps.

It's that wack on the screw head that breaks the threads free. Before I discovered that little trick I broke the Phillips head tip on my 6 in 1 screw driver right off. I later got that same screw free after a few knocks with a hammer.

[posplayr]

It's that wack on the screw head that breaks the threads free.

I'm sure it helps, but when the screw head gets buggered and even the wrench starts to grind out the bolt head, giving it a wrap gets it to bite better