Stator Replacement Tips - Kawasaki Versys Forum
 
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post #1 of 14 (permalink) Old 03-13-2011, 05:08 PM Thread Starter
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Stator Replacement Tips

Just finished replacing the burned out stator in my 09 Versys. The installation was a success and it is once again charging the battery! The service manual has a good guide for the whole process, but here are a few supplementary tips...

1. Make sure you have a torque wrench that does in-lbs

2. Gears might fall out when you take the generator cover off, just be aware. Fried stator anyone?



3. They don't mention the little triangular metal piece bolted to 3 bolts on the generator cover that provides one of the three mount points for the lower fairing. Not mentioned in the '07 SM.

4. Rotor is magnetized which makes it tough to line up the holes when you replace the cover. Took me 3 times, so be patient. Also make sure the idler gear, torque limiter, and shafts are pushed all the way in before putting the cover on.

Installing the stator in the cover was the hardest part. The rubber gasket that seals the area where the wires exit the generator housing is too close to the stator. I barely managed to get it into the slot.

Looks kinda sloppy, but couldn't think of anything short of cutting some of the rubber off. But that could possibly cause a leak.

I'm fairly new to working on motorcycles, so this was definitely a test of my skills. It was fun, but hope I don't have to repeat it.

Hope you have success too!

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File Type: jpg Fried Stator-sm.JPG (101.5 KB, 4205 views)
File Type: jpg Stator Gasket-sm.JPG (80.4 KB, 3311 views)
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post #2 of 14 (permalink) Old 03-13-2011, 05:15 PM
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What causes that kind of failure? Almost looks like it was burning itself up!

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post #3 of 14 (permalink) Old 03-13-2011, 11:28 PM
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Nice pics, jordantk... Is your alternator cover sitting directly on the cement in your 1st pic? I see there's a towel underneath to protect it in 2nd pic. Looks like some stator burn residue stuck to inner cover in upper part of 1st pic. Did it clean off?
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post #4 of 14 (permalink) Old 03-13-2011, 11:35 PM
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What causes that kind of failure? Almost looks like it was burning itself up!
Copper wire windings can short out through resin coating over time from vibrations or impact... It often happens after bike was drropped on its left side.

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post #5 of 14 (permalink) Old 03-14-2011, 11:56 AM Thread Starter
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What causes that kind of failure? Almost looks like it was burning itself up!
I dropped the bike on left side, so I'm hoping this is the cause. I tested out the regulator/rectifier with that kludgy 3 battery test. It passed and now the battery is charging, so keepin' my fingers crossed...
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post #6 of 14 (permalink) Old 03-14-2011, 12:04 PM Thread Starter
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how so? the locator dowels, gears/shafts are all in position on the engine case, so the cover self aligns. it can only be positioned one way and slides right together. don't know how this could be done three times, and with RTV on the mating surfaces in addition to the gasket, you have a major mess on your hands.
The bottom dowel was stuck fast on the bottom screw hole of the generator cover. I couldn't remove it for some reason. Probably could have eventually gotten it off, but would have destroyed it in the process. That might explain some of the problems I had.

Regarding the gasket, it is tough putting that cover on while kneeling on the floor with the magnet from the rotor pulling on the alternator. The first few times didn't work because the gasket was slightly out of alignment and had to pull it off completely to reposition the gasket.
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post #7 of 14 (permalink) Old 03-14-2011, 12:13 PM Thread Starter
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Nice pics, jordantk... Is your alternator cover sitting directly on the cement in your 1st pic? I see there's a towel underneath to protect it in 2nd pic. Looks like some stator burn residue stuck to inner cover in upper part of 1st pic. Did it clean off?
Thanks! Everything cleaned up fine. In the first pic, it was setting on the handles of pliers. Figured out pretty quickly the cement would scratch it up, so grabbed a shop towel.

I ought to send a picture of my "garage", it barely better than nothing.
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post #8 of 14 (permalink) Old 03-14-2011, 07:36 PM
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It's not a big job to make 2 or 3 alignment pins by cutting the heads off long screws. Then the gasket and cover slide right on.

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post #9 of 14 (permalink) Old 11-10-2013, 10:48 AM
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I know this is an old thread but...

Does the silicon go all the way around the gasket, or just in the 2 spots indicated in the manual. Also, do you use threadlock on the cover screws?
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post #10 of 14 (permalink) Old 11-20-2013, 07:39 PM
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Thanks for the tips jordantk, just additional question. Where and how much did you bought the new stator and what is the recommended torque for each nuts and bolts?
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post #11 of 14 (permalink) Old 11-22-2013, 01:18 AM
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Garage
kludgy 3 battery test???
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post #12 of 14 (permalink) Old 11-22-2013, 10:20 AM
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Thanks for the tips jordantk, just additional question. Where and how much did you bought the new stator and what is the recommended torque for each nuts and bolts?
http://ricksmotorsportelectrics.com/aftermarket-stators

For torque check your shop manual for your year....should be in a sticky.

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post #13 of 14 (permalink) Old 11-22-2013, 01:01 PM
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Did you have to use a new gasket? I can't find them anywhere


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post #14 of 14 (permalink) Old 11-22-2013, 01:41 PM
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Did you have to use a new gasket? I can't find them anywhere


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I didn't. Just some black rtp around the rubber grommet.

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