Stator and flywheel for Suzuki GS 400L, 1980

[Guest]

I'm looking for at stator and a flywheel for my Suzuki GS 400L, 1980. My question is - from which models can I use replacement parts and is it possible to buy new items for my model - and if it is possible to buy new parts (stator and flywheel) - any recommendations on brands and websites? By the way, I live i Denmark, Europe, so it would be nice if I could find parts here in Europe.

A little history (on removing the the stator cover) - a lesson to be learned
I thought I only had a problem with my stator (did the measurements on the wires and it was only generating very low voltage - about 5-6 volts when engine was running), but when I finally got the stator cover off (8+ hours - I'll tell you shortly), I realized that the flywheel was broken (about an inch had broken off on the inside of the flywheel). It's possible that I broke the flywheel in my attempt to get the cover off? As I already stated it took me 8+ hour to remove the cover, and here is the reason. I looked in the Suzuki GS 400-450 77-87 Clymer manual and it illustrates that that there are 7 visible screws that has to be removed in order to remove the cover. After 8 long hours truggling with the cover, I almost gave up. I then decided to remove the clutch cover next to the stator cover. To my surprise I found another screw behind that cover and when I removed it the cover came of without any problems . In the 8 hour long process (over two days) I had used a mallet in order to try to loosen the cover (in the end I smacked it pretty hard - I was frustrated). It is possible that I may have have damaged the flywheel in that proces. The lesson to be learned - "don't always trust the manual - listen to your wife"! In the process, my wife had noticed my frustration and at one point about halfway in the process she said "there probably is a hidden screw somewhere" But I told her "No, look here in the manual, there are only these 7 visible screws"

I'm a new user to this forum since I just bought my Suzuki GS, but I already love it. A lot of top notch information in here.

[geol]

Mugge, Welcome! First thing is to edit your profile signature so that your bike year/model appears. If you post and forget to mention which bike you own, I am sure someone else will bring this up. Second, if you need to do a parts cross reference, go to a site that sells OEM parts. I personally use Partzilla.com but there are many and prices/shipping will vary. In Europe, there is cmsnl.com which is a good site as well. In any case, select OEM pars, your bike year/model and then the section of the bike relevant to the parts fiche you need to look at. Get the part numbers needed as there will often be several; not just the main part you are interested in. Write them down then do a search on that part number right on the site. It will tell you which models the part number applies to. Only issue you will run into is that if you look up body parts; say you look up side covers, the part number will be specific to the paint color. Keep in mind that Suzuki keeps MANY parts available and in stock so these parts will often not be available in the aftermarket. Last note is that the Clymer manual generally has a LOT of mistakes as you probably have already guessed. Good luck and I can't give any advice on your bike model as I am not at all familiar but whacking away with a rubber hammer on a cover likely didn't break any part underneath unless the cover somehow got damaged.

[Mugge]

Thanks, Geol. The cover is still intact and looks fine, so maybe the problem to begin with wasn't the stator, but the flywheel? I'll follow your advice in my search for parts and look at the sites you recommended to begin with.

[Gorminrider]

Tip: I don't think you are not using the best manual for that engine...the Clymer is pretty much for the American models (450cc with 2 valves for each cylinder)with round cam-end covers....I am expecting your 1980 400 cc to have square cam-end covers and 4 valves for each cylinder....and, to say "GS40X" on the engine
The bikes are pretty similar everywhere else but the engine and carbs are different in several important respects.
Also, the GS400 and 425 the Clymer refers to are 1977-1979 models-even more different than the 450 per your bike- not your 1980 GSx400 which was not found in the ' States....
Look for a Haynes manual and/or

go here

http://members.dslextreme.com/users/bikecliff/

and download these two manuals GS250T-GS300L '82 Service Manual (91MB)
GSX400 Service Manual (5.2MB)