Stator replacement

[njbaker2]

I am about to replace the stator in my '81 gs650e and before I take on this task I am concerned with how I will be able to actually remove the philips head bolts holding the cover on the bike. My guess is that these have never been removed so I would like any advice on how to remove these.

[850GT_Rider]

I am about to replace the stator in my '81 gs650e and before I take on this task I am concerned with how I will be able to actually remove the philips head bolts holding the cover on the bike. My guess is that these have never been removed so I would like any advice on how to remove these.

I'd start by getting an impact driver, otherwise you'll just strip the heads.

http://www.northerntool.com/shop/tools/product_36882_36882

When you put it back together, use new gasket and socket-head cap screws.

[gs850cafe]

impact driver is a must with these bikes...i picked one up at my local napa for 13 bux..

now if your cheap like me and forgot to order the gasket and or screws...i just re-used my screws and gasket(light coat of sillycone)

no leaks yet

oh and also when i first replaced my stator i couldnt get it to break loose with the impact driver...a little bit of heat works froma propane torch(about 10-20 sec on the screw) an out it came

[tom203]

Impact driver is a must- some heads can be grabbed with vice-grips to break loose. Removing old gasket thoroughly and carefully is time consuming, but a must to ensure a tight seal; plan on getting new screws, most are same length, but a couple (?) are different, so note location of oddballs.

[BassCliff]

Greetings and Salutations!!

Hi Mr. njbaker2,

I've documented my experience: Stator Replacement.

Let me dump a TON of information on you and share some GS lovin'.

I just stopped by to welcome you to the forum in my own, special way.

If there's anything you'd like to know about the Suzuki GS model bikes, and most others actually, you've come to the right place. There's a lot of knowledge and experience here in the community. Come on in and let me say "HOoooowwwDY!"....

Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. This is what NOT to do: Top 10 Newbie Mistakes. Now let me roll out the welcome mat for you...



Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[cowboyup3371]

What the others said about the impact driver and replacing them. Use a piece of cardboard to place each screw in taking note of where on the cover it came from (draw an outline or something). While you are there, read up on the proper way to rewire the new stator to the R/R and make sure you use blue loc-tite on all internal screws or you could end up with a rotor looking like this:



That was from my stupidity of not ensuring everything was securely fastened the first time I replaced my stator.

Also, this will be the perfect time to thoroughly go through your wiring harness and clean up EVERY connector/terminal. If you've fried your stator, I'll bet you have a corroded connector some place. Save yourself the money and headache of repeating this maintenance by doing that. Again, experience from my own laziness the first time.

[BassCliff]

Hi,

I forgot to mention, you might want to pick up a bolt kit from Z1 and replace all those nasty phillips screws with stainless hex head fasteners.

Thank you for your indulgence,

BassCliff

[njbaker2]

Thank you senior members for the great advice. It was actually the guide to stator replacement by BassCliff that I found first on Google that led me to the GSResource forum. I wish I would have found this 4 years ago when I first got my bike. Thanks to the impact driver and the new bolt kit from Z1 enterprises, I am ready to install the new stator, after a lot of polishing. I'm sure I will have many more questions in the near future. Thanks again for all the help!