How to change the stator on a DL1000 - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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  #1  
Old 06-03-2008, 04:34 PM
MZBuckeye's Avatar
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Default How to change the stator on a DL1000

Bike's battery won't charge? It might be your stator. First diagnose the charging system per the service manual, and if you determine your stator is bad, here's how you change it out:

1. Remove seat, left side panel under seat and plastic skid plate, disconnect battery and drain oil (not sure if you need to do this, but I did). I also had the tank raised because I changed the spark plugs:



2. Disconnect the two black connectors near the regulator/rectifier underneath the side panel, below the seat:



3. Snip the zip tie that holds the harness to the frame:



4. Remove all the bolts around the left side engine case and the clutch slave cylinder:



5. Remove the left side engine case and feed the connected wiring harness off the bike from behind the frame. You'll find the stator bolted to the back of the engine case with 6 allen head bolts. Remove them and remove the bad stator, and remove and discard the gasket between the engine and the engine case you removed:





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1997 Kawasaki ZG1000 Concours, [COLOR="DarkGreen"]GREEN[/COLOR]

Old bikes:
2001 Kawasaki ZRX1200R, [COLOR="Lime"]GREEN[/COLOR], sold
2005 HD FXDCI, sold
2003 Yamaha FZ1, "Bee", sold
2005 Suzuki DL1000, Black, sold
2002 Yamaha FZ1, Silver, sold
1991 Kawasaki Ninja ZX-6D, sold
1982 Honda Sabre 750 V45, sold

Last edited by MZBuckeye; 06-03-2008 at 04:47 PM.
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  #2  
Old 06-03-2008, 04:41 PM
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Grab your new gasket and stator. I ordered mine from MR Cycles to the tune of about $225 shipped for both:



Old vs. New



Bolt the new stator in place, and press the rubber grommet into the slot in the engine case:



Replace the gasket, and bolt the engine case back into place:



Feed the wiring harness behind the frame and back to the regulator/rectifier. Connect the electrical connectors:




Zip tie the harness into place, bolt the clutch slave cylinder back into place, and replace the side panels and the seat:

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1997 Kawasaki ZG1000 Concours, [COLOR="DarkGreen"]GREEN[/COLOR]

Old bikes:
2001 Kawasaki ZRX1200R, [COLOR="Lime"]GREEN[/COLOR], sold
2005 HD FXDCI, sold
2003 Yamaha FZ1, "Bee", sold
2005 Suzuki DL1000, Black, sold
2002 Yamaha FZ1, Silver, sold
1991 Kawasaki Ninja ZX-6D, sold
1982 Honda Sabre 750 V45, sold
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Old 06-03-2008, 04:44 PM
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That's it! Fill it up with oil, re-connect the battery and fire it up. Finally, for god sakes wash all the filth off that bike!!!

Questions?
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1997 Kawasaki ZG1000 Concours, [COLOR="DarkGreen"]GREEN[/COLOR]

Old bikes:
2001 Kawasaki ZRX1200R, [COLOR="Lime"]GREEN[/COLOR], sold
2005 HD FXDCI, sold
2003 Yamaha FZ1, "Bee", sold
2005 Suzuki DL1000, Black, sold
2002 Yamaha FZ1, Silver, sold
1991 Kawasaki Ninja ZX-6D, sold
1982 Honda Sabre 750 V45, sold
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Old 06-03-2008, 05:38 PM
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Very nice Dan!!!

Good to see it back together!!!
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Old 06-03-2008, 08:24 PM
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Did you consider the higher output stator that is out there and if you did why did you decide to go stock?

Nice write up, BTW!
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Old 06-03-2008, 09:36 PM
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I only found one other stator available, and it was an OEM replacement, nothing I found about it suggested that it was of higher power. I did read about one called Electrosport that was of higher power, but they quit making one for the 1000 due to fitment issues. I decided OEM was the way to go.
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1997 Kawasaki ZG1000 Concours, [COLOR="DarkGreen"]GREEN[/COLOR]

Old bikes:
2001 Kawasaki ZRX1200R, [COLOR="Lime"]GREEN[/COLOR], sold
2005 HD FXDCI, sold
2003 Yamaha FZ1, "Bee", sold
2005 Suzuki DL1000, Black, sold
2002 Yamaha FZ1, Silver, sold
1991 Kawasaki Ninja ZX-6D, sold
1982 Honda Sabre 750 V45, sold
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Old 06-04-2008, 12:38 AM
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Quote:
Originally Posted by MZBuckeye View Post
I did read about one called Electrosport that was of higher power, but they quit making one for the 1000 due to fitment issues. I decided OEM was the way to go.
That's the one I was thinking about (couldn't remember the name) and I hadn't heard about the fitment issue. That kinda makes your decision a little easier...
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  #8  
Old 06-04-2008, 07:54 AM
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Great Job Dan....... what are the torque values for the bolts that mount the stator, and did you use any thread lock?
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  #9  
Old 06-04-2008, 09:30 AM
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Quote:
Originally Posted by Big B View Post
Great Job Dan....... what are the torque values for the bolts that mount the stator, and did you use any thread lock?
Um, good question. I'm not sure, so I just used a common sense amount of torque. They came out pretty easily, so the torque value is not too high, and there was no thread lock used from the factory so I didn't use any.
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1997 Kawasaki ZG1000 Concours, [COLOR="DarkGreen"]GREEN[/COLOR]

Old bikes:
2001 Kawasaki ZRX1200R, [COLOR="Lime"]GREEN[/COLOR], sold
2005 HD FXDCI, sold
2003 Yamaha FZ1, "Bee", sold
2005 Suzuki DL1000, Black, sold
2002 Yamaha FZ1, Silver, sold
1991 Kawasaki Ninja ZX-6D, sold
1982 Honda Sabre 750 V45, sold
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  #10  
Old 06-08-2008, 01:29 PM
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Great write up, Dan. Sorry you had to learn how to do this, but glad you shared the experience with us.
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