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Replacing the Stator, 1st Generation Venture

  Author: Craig Dimitroff
  Views: 17166     Votes: 5
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The Problem


Defective Stator

I was able to trouble shoot and identify the problem by using testing procedures found here. The motorcycle was a significant investment and it was great to find this site for help.

My Motorcycle is a 1989 Venture 1300. The battery would not keep a charge and after about an hour riding, would drop to a level where it would stall out and could not restart.

Using a volt meter on the battery and the engine at idle (about 1000 rpm) the volt meter registered only the battery current charge. With the engine revved up to 3000 rpm it would only go up .1-4. i.e. 12.4 to 12.5 - 12.9.

As you can see in the diagram (image 1) the stator was indeed bad. The wire was burned completely off and the bottom half of the ring was charred.

Removing the Stator


Parts Removal

The stator is located behind the crank case cover depicted by the arrow in (image 2). The area outlined in green is what I needed to remove to get to the cover.

Remove the battery cover
Remove the side cover
Remove foot board & pedal
Remove front scoop
Remove radiator cover
(necessary to get to upper fairing screws)
Remove engine guard
(necessary to get to lower fairing screws)
Remove lower fairing (Yellow points)

Remove the Crank Case Cover


Cover Removal

Follow the stator wire and remove from the frame.
I had to cut 3 flex ties to remove the wires.

Shown (image 3) is the cover already removed but where the yellow dots are is a where you remove the cover bolts. You will need a metric allen key.

Remove all of the cover bolts from around the cover.

I needed to use a flat head screwdriver to gently break the seal and pull the cover off.

The gear indicated by the white arrow came off when I removed the cover. It just slides back on and fits nicely with the other two gears on the left and right.

The stator is secured inside the removed cover by three screws.

The area indicated by the green outline was a cover that DID NOT need to be removed.

Order Your Parts

You will need: GASKET, CVR1 #3JP-15451-00-00
I also needed to order the other cover gasket that I had removed:
GASKET,CRCS COVER 2 #3JP-15461-00-00
Order stator: STATOR ASSY # 26H-81410-12-00
*The OE part is expensive but aftermarket versions are available at more reasonable prices. Some have a higher output than the OE part also, which could be handy for powering added accessories.

Removing the Stator from the Cover


Stator Screws

The stator is secured by three screws (white arrows).

The wiring is secured into the cover by a bridge plate and comes out by unscrewing two (2) screws (yellow arrows) and lifting up. The stator and attached wiring harnes lifts up and out easily. Note: The screws may have Loctite on them and could be difficult to remove. It may be necessary to apply heat to help loosen them.

Then I used a razor blade to carefully scrape the old gasket from both the cover and engine ridges.

Reassemble by Reversing the Process

Thanks to the community for all of the other tech help.

Last update: 12:36 AM Thursday, December 15, 2011

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