450 Electrosport stator

[pete]

That new stator looks... well... new

Can I suggest...

http://www.z1enterprises.com/Bolt-Set--Suzuki-GS450-ET-ST-EX-SX-EZ-8082--Stainless-Steel-Set-702-1156.aspx

You'll get everything you need right there plus some spares, at least mine had spares anyway... very nice replacement...

[davidduarte]

here's the scan of the gasket:

[davidduarte]

well, it's all back together now. I used some RTV for the grommet, but it will have plenty of time to cure, as my wife and I are headed to Maine tomorrow for a few days. Now I'm just hoping and praying that everything is copacetic and doesn't leak or otherwise malfunction, as I've been at it for about 2 hours tonight and my back is killing me. Actually, it was less than that, because part of that time I also changed the oil in my car. I'll let you know how it goes when I get back.

[pete]

Nice one David, and good idea on scanning the gasket!

Hope you have a nice few days and looking forward to seeing how it goes when you get back.

My wife and I would love to visit Maine one day... not sure if it'll happen or not though as I'm not sure if we could stomach the flight...

[davidduarte]

I forgot to mention that as I sat down to secure the case cover, I realized that the hex head screws would not work, as the holes are somewhat recessed, so I ended up re-using the old philips head screws. I like the button head cap screws better than the socket head screws, as the socket heads have a higher profile. The button heads are very similar in profile to the original philips screws. This isn't as important on the 8 screws that are immediately visible on the outside of the case, but I'm concerned about clearance problems with the 2 screws behind the sprocket cover. With a socket head, I'm not sure I'd be able to get the sprocket cover back on. Pete, did you have any trouble in that area?

[pete]

No troubles at all David, everything went in easy and I had no clearance issues anywhere at all. The two in the signal generator area on the right side case cover were fine too.

[davidduarte]

Eureka! I had put the new stator in, put some RTV on the grommet where the wires came through the case, socked all the screws back in, and left it over the weekend. Came home and...still not getting great voltage at the battery. Today I went to Advance Auto Parts and got a mini-fuse holder and some 15 amp fuses, along with some ring terminals. I replaced the old fuse holder, put in all new bullet connectors, and also extended the black wire from the R/R to the grounding wire from the negative terminal on the battery. I also replaced said grounding wire. Fired it up, and finally got 14 + volts at 4000 rpm

[pete]

Excellent news David! So you had two problems? The toasted stator and the dodgy connectors and fuse holder?

[davidduarte]

Excellent news David! So you had two problems? The toasted stator and the dodgy connectors and fuse holder?

I'll have to post pictures later on after I get home, but yes, some of the wiring was more or less buggered. The new wire I used was 12 gauge, so I'm sure that has made a difference as well. Good to give the electrons a bit bigger pipe to flow through I want to do the coil relay mod on this bike, but I'm not quite sure where to start. I have seen some of the threads on this mod, but haven't really had time to fully digest any of them.

[pete]

If you do the cleanup right, you shouldn't need the coil relay mod. I've gotten my voltage drop down from around 2v to 0.2 - 0.5v by cleaning everything up, including the guts of the ignition and kill switches which appeared to cause the most grief.

After doing that work, the coil voltage is generally just over 12v which I'm happy with.

I've yet to test my charging system fully, so that's all just with a car battery attached for the moment.

[davidduarte]

If you do the cleanup right, you shouldn't need the coil relay mod. I've gotten my voltage drop down from around 2v to 0.2 - 0.5v by cleaning everything up, including the guts of the ignition and kill switches which appeared to cause the most grief.

After doing that work, the coil voltage is generally just over 12v which I'm happy with.

I've yet to test my charging system fully, so that's all just with a car battery attached for the moment.

I may not need the mod, but I want to add a 12 volt plug and possibly wire up a horn relay too, so I figured I'd do it all at once. Anyway, here's the new wiring:





and some of the crummy old wiring:

[pete]

Love your work David, looks like you got the common ground done too!

Your crummy old wiring looks very similar to what mine was which is now gone also as part of my electrics relocation.

A 12v accessory plug and horn relay are definitely good ideas, so I can see why you were thinking the coil relay mod...

I haven't looked at the detail of the mod, but I think there's a way you can do it for the bigger bikes without cutting up the loom, whereas I think on our 450's we'd have to cut the loom for it to work...

[davidduarte]

as you can see from one of the pictures, the chain guard is missing. I replaced it a few years ago, but this one broke in the same place the old one did, at the rear mount point. I've been looking on eBay for a metal replacement, although I'm not sure if it will fit my bike.

[pete]

Interesting... I haven't had any grief with mine...

[davidduarte]

speaking of dodgy wiring, I thought I'd look around some more, and found this:



I squared that away with new connectors. My gas mileage had been lower than normal lately, so I figured I'd clean out the air filter. Here's what I found when I opened the air box:



Damn chipmunks! Guess I have to go get some poisoned bait and take care of those little bastards.