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Replacing Your Generator Stator and Your Rectifier/Regulator |
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Written by Randy Fox (Randysgym)
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Saturday, 20 October 2007 |
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Page 3 of 6
Important Tip: I have listed part numbers below. However, manufacturers change them for inventory purposes, and occasionally improve parts further. Therefore, be sure to check for availability of parts with better specs than those listed below.
- Stator, Yamaha part#: 5VN-81410-01-00, or Electrosport part#: ESG752.
- Regulator/Rectifier, Yamaha part#: 5VN-81960-00-00, or Electrosport part#: ESR440. Note: If you have a chrome cover for your existing rec/reg it won't likely fit over the replacement part. The newer ones are slightly bigger.
- Stator bolts (quantity: 3). Only needed if you destroy or bung the head(s) of these stubborn items. Yamaha part#: 90149-06019-00, or any M6 x 1.00 x 19mm bolts will do.
- Silicone form-a-gasket (like Versa-Chem 273 High-Temp, Black, Silicone, Gasket Maker), available at most auto parts and home improvement stores.
- Gasket removal liquid (like Versa-Chem Gasket Remover spray), for cleaning off the old gasket remnants. Available at most auto parts and home improvement stores.
- Generator cover gasket. Yamaha part#: 5PX-15461-02-00.
- Generator cover bolt washer. Yamaha part#: 90430-06014-00, optional but recommended. This is the little washer for the lower, long bolt.
- Exhaust header gasket, for the front pipe. Use either Yamaha part#: 3EG-14613-00-00, ($3 to $6ea), or AutoZone part#: Fel-Pro 23588, (less than $1.50ea).
- Dielectric (silicone) grease, to help reduce corrosion in electrical connections, available at most auto parts and home improvement stores.
Tools
- 5mm hex wrench.
- 8mm hex wrench for Removing/installing exhaust header.
- Modest metric or SAE socket wrench set, for removing the exhaust tail-pipe, as needed.
- T-30 Torx wrench, for the stator. This is for removing the stator from the inside of the generator cover. Note: I'm told that some Road Stars have phillips screws instead of Torx.
- A piece of strong string at least 6 feet long. Alternately, you can use an electrician’s Fish Tape. Optional, if you wish to route the stator wires through the same path as stock, without major disassembly of the bike.
- Soldering pencil, if you will not be using Yamaha O.E.M. replacement parts. This is to solder connectors on to wires. Alternately, you can use crimp-on connectors.
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