Anyone ever replace a stator on any bike ?

[pearljam724]

I need to replace the stator on Suzuki GS. All of the aftermarket stator wires are not color coded like the Oem stators. All of the aftermarket stator wiring is the same color. Does it not matter which wires are mated to the stock harness ? I'm pretty sure that's the case. Having said that, why in the hell would the stock stator wiring be different colors ?

[jabcb]

Join the GS forum for lots of useful info: http://www.thegsresources.com

The GT-series triples have car-like 3-phase alternators with field coils. As a result, the stators & rotors are reasonably reliable.

Suzuki went a bit crazy with the early GS-series alternators.
They started with 3-phase alternators with permanent-magnet rotors but used one of the phases as a lighting coil.
And the result is that stator problems are common.

There are two different types of rectifiers/regulators for this type of alternator: shunt & series. The stock R/R are shunt type — they operate the alternator at maximum output & turn the excess output into heat. Series R/R are a much newer design — they control voltage by varying the alternator output.

The cats meow solution for your GS-series bike is a new aftermarket stator + modern series R/R. See the GS forum for details.

Back to your question...
The 3 phases are identical on aftermarket stators. The three stator wires are yellow because it doesn’t mater how you hook them up.

[pearljam724]

Thank you, very much. I just replaced the rectifier with an original Oem. Hoping that was the issue. It didn't solve the issue of replacing my third battery in a year. Only thing I haven't changed to this point electric wise is the stator. Just hope the stator didn't fry the new rectifier. I fear that and getting the dreaded Phillips screws removed mounting the stator to the ciover. I know when it's time, they are gonna be dreadful.

[jabcb]

Get some JIS screwdrivers is you don’t already have them.

Do you have an early model with separate rectifier & voltage regulator?

You can save yourself a good bit of aggravation by wiring up that new stator directly to a new modern R/R.
Bypass the existing wiring, and connect the 3 stator yellow wires to the corresponding 3 wires on the R/R.

[pearljam724]

Yeah, I have JIS bits. That's not always easy either. I have a lot model, 87. No regulator. Maybe, I'll get lucky with screws. No exaggeration, when it comes to those Phillips heads. It's always one damn screw that gives me a problem, have to drill it out, etc.

[jabcb]

Did you mean a 78 model? Which one?

[pearljam724]

I meant to type late model, 87. It's a GS 450. I've owned a couple dozen bikes in my life time. New, old, big cc, little cc. By far this bike is the best all around bike for the money I've ever owned. It has plenty of power, gets 58 miles to the gallon, comfortable, handles great, fantastic condition and I only paid $800 for it. But, it's been frying batteries every couple
months. That started last spring. I ride it a lot. I just ordered a new stator, but haven't received it yet. It's the only electrical component on the bike that isn't new. If I drift start it. It will run all day, till I shut it off. Then the battery doesn't have enough juice to turn the starter. If I install a new battery it fires first push of the starter button. No kidding, It's been through 4 new batteries since last spring. Odd thing is, If I remove the battery to charge it. Reinstall it, the battery still won't turn the starter. All recent batteries did the same thing. The stator must be frying the batteries. I haven't test the voltage output with a multimeter yet. I will do that before installing the new stator. I should have done all those tests a long time ago. But, I was lazy. And as much as I love working on bikes. I hate working on this one. Everything is a pain to access, remove etc. Bad design on these bikes. Carbs, battery, air box are a nightmare to remove. A few years ago I tinkered around on GS resources. But, there isn't enough traffic on it. So, I haven't been on there much since. This is a much better site and I'm sure a lot of guys on here own or owned GS's.

[pearljam724]

On the conversation about JIS bits. I would have to think that the screw driver that comes in Suzuki tool bags is JIS ? Not sure, though ?

[Alan H]

Sounds like there's some poor connections somewhere. I would be checking earths and earth cables for condition.

[jabcb]

Your bike has a shunt-type rectifier/regulator.

Go with a modern aftermarket stator & modern aftermarket rectifier/regulator. Wire the 3 stator yellow wire directly to the rectifier/regulator. Add an additional ground to the R/R ground wire.

And check the voltages.

[pearljam724]

My ground wires are fine. I've gone through all the wiring a few times. What classifies a shunt rectifier ? You mention to wire the stator directly to the rectifier. Mine has all original or replaced original parts and the stator is wired directly into the rectifier. I believe that's the case because the late model GS's have no regulator like the early models. Even though my rectifier had no ground wire attached to it and the frame. I imagine it would be helpful to attach one to a mounting screw and the frame just like the GT's. You can never have too many grounds the way I understand. My rectifier has a black wire that runs to it internally from a connector. But, doesn't appear to be grounded directly to any metal surface ?

[jabcb]

What rectifier are you using? (Is it the original, part # for Suzuki item, link for aftermarket part, etc.)

The Suzuki GT triples & early GS models have separate rectifiers & voltage regulators.
Later GS models have a rectifier/regulator, which combines the rectifier & voltage regulator into a single part.

I think that maybe you have the wrong part.
Post a pic if you aren't sure of exactly what you have.

[pearljam724]

You're a little confused. Yes, what you said in your last post is the case and I mentioned. This is what mine looks like and is original design to my 87. Mine looks exactly the same, but Rick's is an aftermarket of course. https://www.ebay.com/itm/281970146197" onclick="window.open(this.href);return false;

[jabcb]

The Rick’s part you got is a rectifier/regulator.

[Tom Garcia]

I have an 83 GS1100 and replaced the stator and R/R with new parts from Electrex when I bought it. With less than 10K miles over the last 10 years, the charging system is shot again. It is the perm magnet setup used on the GS series as explained at the GS Resources in their "Stator Papers"...an excellent read. With the shunt type regulator it "shorts" excess voltage to ground causing the stator windings to overheat and they eventually short out. Regulator also gets worked hard... I will rewind my original stator core and have bought the Shenzhen series R/R used on Polaris and other products. Less than $100 with new crimp wiring connectors. This change should last the rest of my or the bikes life.... Also, the older shunt regulators really don't treat non-traditional acid batteries nicely. I've been through a couple AGMs in the GS and found info that it was probably the old school shunt R/R...