Changing The V-Star 1100 Stator
Contents
1. T P S rightside360 JP regulator360 JPG do the other side the rectifier The regulator is located on the lower RIGHT side of the engine below the battery The top photo shows the location of both the battery and rectifier The bottom photo shows the battery amp rectifier with covers removed At this time remove the battery cover Battery Cover 1 10mmH Page 15 of 23 floorboard_1 jpg Depending on what exhaust configuration you have you may or may not have to remove the slip ons I chose not to And due to the many configurations of exhausts I won t get into the details Remove the floorboard and Master Cylinder There may be a ty wrap that you will need to cut to prevent any stress Carefully lower both You do not need to disconnect anything from either at this point Master Cylinder bolts 2 10mmH Floorboard Bolts 2 14mmS Page 16 of 23 Remove the front lower exhaust pipe nuts Then remove any support holding the exhaust at the tail end You want the exhaust assembly to be free Engine Exhaust Nuts 2 XmmsS or B exhaust_1 jpg Carefully lower the exhaust You do not have to completely remove the exhaust You will need to make sure you don t put any stress on the exhaust bolts So take it easy exhaust 3 jpg Page 17 of 23 Remove the rectifier cover bolt Then remove the cover note the other end top of the cover just snaps in place cover 1 10mm2. gt a 74 E A bike stand is required and will make the whole job safer and easier Just be sure the bike is stable ALWAYS Remember Safety First bikeleftside360 JPG First you need to drain the oil Place a container under the engine oil drain bolt Remove the engine oil fill cap and O ring Remove the engine oil drain bolt amp gasket Let the oil drain completely Oil Drain Bolt 17mmB be eco friendly recycle oildrain360 jpg Page 3 of 23 flbd_shifter360 jpg shifterclamp360 jpg Remove the following from the left side of the bike floorboard and shifter 2 14mmS shifter linkage 10mmB Note The shifter linkage shaft has a small indentation on it Be sure to get a good look how it aligns with the gap in the clamp Page 4 of 23 Remove the following from the left side Drive train cover 4 SmmH Clutch Linkage Cover 3 5SmmH Kick Stand Bolts 2 14mmS Be careful the kickstand sensor switch wire is very short Disconnect the clutch cable by grabbing the lever with a pair of pliers rotate counter clockwise until you can remove the cable end from the bracket cableClutch1360 jpg Page 5 of 23 tywrap360 jpg Disconnect the stator and speed sensor connectors Remove the Left crankcase cover Crankcase Cover Bolts 14 SmmH There are different length bolts used so you may want to number them as shown this will make it easier to re install them Note when you
3. batteryvolts jpg If all is well then re Install the battery cover Bolt 1 5mmH 5 1 ft lb le Rectifier Ta Regulator J b7 pr af fom 5 Tel f Tai 4 oi P ww i re kA rightside360 JPG Page 21 of 23 And finally GO RIDING Page 22 of 23 ft Ib xx Nm mikg ft lbs Conversion Table ft Ib 28 9 29 7 30 4 31 1 31 8 32 5 33 3 34 0 34 7 35 4 36 2 36 9 37 6 38 3 39 1 39 8 40 5 41 2 42 0 42 43 4 44 1 44 8 45 6 46 3 47 0 41 1 48 5 49 2 49 9 ft Ib 90 6 51 4 52 1 52 8 53 5 54 2 55 0 50 56 4 57 1 57 9 58 6 59 3 60 0 60 8 61 5 62 2 62 9 63 7 64 4 65 1 65 8 66 5 67 3 68 0 68 7 69 4 70 2 70 9 71 6 m kg 10 0 10 1 10 2 10 3 10 4 10 5 10 6 10 7 10 8 10 9 11 0 11 1 11 2 11 3 11 4 11 5 11 6 11 7 11 8 11 9 12 0 12 1 12 2 12 3 12 4 12 5 12 6 12 7 12 8 12 9 ft Ib 72 3 73 1 73 8 74 5 75 2 715 9 76 7 71 4 78 1 78 8 79 6 80 3 81 0 81 7 82 5 83 2 83 9 84 6 85 3 86 1 86 8 87 5 88 2 89 0 89 7 90 4 91 1 91 9 92 6 93 3 m kg 13 0 13 1 13 2 13 3 13 4 13 5 13 6 13 7 13 8 13 9 14 0 14 1 14 2 14 3 14 4 14 5 14 6 14 7 14 8 14 9 15 0 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 9 Page 23 of 23 ft Ib 94
4. 0 94 8 95 5 96 2 96 9 97 6 98 4 99 1 99 8 100 5 101 3 102 0 102 7 103 4 104 2 104 9 105 6 106 3 107 0 107 8 108 5 109 2 109 9 110 7 111 4 112 1 112 8 113 6 114 3 115 0 mikg 16 0 16 1 16 2 16 3 16 4 16 5 16 6 16 7 16 8 16 9 17 0 17 1 17 2 17 3 17 4 17 5 17 6 17 17 8 17 9 18 0 18 1 18 2 18 3 18 4 18 5 18 6 18 7 18 8 18 9 ft Ib 115 7 116 5 117 2 117 9 118 6 119 3 120 1 120 8 121 5 122 2 123 0 123 7 124 4 125 1 125 9 126 6 127 3 128 0 128 7 129 5 130 2 130 9 131 6 132 4 133 1 133 8 134 5 135 3 136 0 136 7 mikg 19 0 19 1 19 2 19 3 19 4 19 5 19 6 19 7 19 8 19 9 20 0 20 1 20 2 20 3 20 4 20 5 20 6 20 20 8 20 9 21 0 21 1 21 2 21 3 21 4 21 5 21 6 21 7 21 8 21 9 ft Ib 137 4 138 2 138 9 139 6 140 3 141 0 141 8 142 5 143 2 143 9 144 7 145 4 146 1 146 8 147 6 148 3 149 0 149 7 150 4 151 2 151 9 152 6 153 3 154 1 154 8 155 5 156 2 157 0 157 7 158 4
5. Changing The V Star 1100 Stator written by Dragonbird Norwestars ISRA This is my personnel attempt to document changing out the stator on a Yamaha V Star 1100 This should be used as a guide only I assume NO responsibility for any mistakes When in doubt refer to the manual The bike I used is my own 2002 V Star 1100 A lot of the info is per the Yamaha Service manual Be sure to check the manual for your particular bike Here s what I tried to maintain Cautionary notes in bolded RED note and mark the alignment Torque values in bolded BLUE 7 2 ft lb 86 4 inlb Quantity of bolts nuts or screws 3 Wrench sizes in bolded GREEN 10mmxX the x S socket B boxed end H hex Personal comments in italics Safety First Actions to perform in normal text Have fun and ride Items Needed New Left crankcase cover gasket 4 qts Crankcase Oil and filter Stator amp Rectifier Replacement Tools Needed Torque Wrench 4mm hex driver tip Smm hex driver tip 10mm socket 14mm socket 10mm boxed end wrench 17mm socket oil drain plug a wrench may be used Threadlocker blue Locktite 242 When re assembling be sure to use the threadlocker Page 1 of 23 Here are both the old stator Left and the new stator Right bothstators jpg Page 2 of 23 Se Ea Pe i 4 S ae For removal of the Stator you will need access to the LEFT side of the E N i bike i pi i jag 8 1 i __4
6. H cover jpg Remove the rectifier There are 2 fiber washers that go behind the regulator rectifier bolts 2 XmmS regulator 2 jpg Page 18 of 23 Unplug the cable by pressing on the tab and pulling re gulator 3 l jpg Old rectifier bolts and fiber washers regulator 5 jpg Page 19 of 23 New rectifier bolts and fiber washers Attach the cable to the New rectifier and install on the housing Torque Rectifier bolts 2 Snug xx ft lb NOTE I can t find the torque spec for the regulator bolts the bolts go into a metal clip which isn t very strong so just make the bolts snug Re Install the rectifier cover Torque cover bolts 1 10mmH 5 1 ft lb With the lower exhaust pipe removed at this point you may want to change the oil filter or install an oil filter relocation kit Re Install the exhaust pipe system Stock Torque Pipe and Muffler bolts 2 10mmH 14 ft lb Torque Muffler Bracket Bolts 2 xxmmH 18 ft lb Torque Engine Exhaust Nuts 2 xxmmsS 14 ft lb Re Install the Master Cylinder and Floorboard Torque Master Cylinder Bolts 2 10mmH 17 ft Ib Torque Floorboard Bolts 2 14mmS 46 ft lb Page 20 of 23 Now let s test it With the engine OFF Measure the voltage DC across the battery It should read about 12 4 12 9 volts Start the bike Measure the voltage across the battery but this time rev the engine The voltage should be between 14 1 and 14 9 volts
7. r connector and the new speed sensor connectors Pull protective boot down over the connectors and re attach note your cables should be about 4 5 inches long than shown This photo was taken using the prototype which had shorter wires At this point you can start the engine and make sure everything works Do not run for more than a few seconds remember no oil yet IF THE ENGINE IS ROUGH RUNNING OR BACKFIRES SWAP THE GREEN AND BLUE WIRES FROM THE PICKUP COIL Page 12 of 23 Re install the following on the LEFT side of the bike clutch cable clutch adjusting cover 3 Torque the bolts 5mmH 7 2 ft lb 86 4 inlb Drive train Cover 4 5mmH 5 1 ft lb 61 2 inlb kickstand 2 Torque the bolts 14mmS 46 ft lb Kickstand360 JPG Also install the following on the LEFT side of the bike shifter linkage note the alignment Torque the bolt 10mmB 7 2 ft lb 86 4 inIb floorboard w shifter 2 Torque the bolts 14mmS 46 ft lb flbd_shifter360 jpg Page 13 of 23 Verify installed or install the engine oil drain bolt and gasket Torque the bolt 17mmS 31 ft lb oildrain360 jpg Fill the crankcase with oil Without filter replacement approx 3 2 US qts With filter replacement std filter approx 3 3 US qts With relocation filter replacement approx 4 3 US qts Be sure to check the engine oil level as your filling the crankcase Page 14 of 23 Ok now let s Rectifier Regulator
8. remove the engine side cover some oil will drain out so be sure to use a drip pan or put down some plastic sheeting When the cover is removed you may find the wires ty wrapped Carefully cut the ty wrap Page 6 of 23 amp starterGears1360 jpg Once the cover is removed take a look at the starter gears Note here in the top photo the gears have slipped out of place If this happens and it probably will you will need to move them back in place then push the center pin back in It s kind of tricky but you can do it Basically push the gears UP while pushing the pin in also turning the flywheel clockwise will help a lot Top photo show the gears dropped the bottom photo shows them in place When the gears are in their proper place the center pin sticks out about 1 2 inch 0 480 Page 7 of 23 amp Look at the inside of the left cover plate Look at the hole that the shifter shaft goes thru There is a washer that goes here If the washer is stuck to the cover remove it a put it on the shifter shaft E washer1360 jpg Page 8 of 23 statorbolts3 60 jpg This is the inside of the left cover Note the location of the Guide Pins These may be either in the cover or still on the engine If possible put them both into the appropriate holes on the engine They can be loose so don t lose them The stator is that thing in the middle Above the stator is the pickup coil Now remove the 6 bolt
9. s indicated There are 3 on the stator 2 on the speed sensor and 1 on the bracket Stator bolts 5mmH Pickup Coil bolts 4mmH Bracket bolt 4mmH Once the bolts are removed lift out the stator and pickup coil Note that the pickup coil may need a little persuasion to get it free Page 9 of 23 P intialinstall jpg Clean off any remaining gasket material from both the engine and the cover Be careful not the scratch the surfaces Also be sure to clean the gasket surfaces thoroughly when your done removing the old gasket material Install the new stator into the left engine cover Put the 2 wires BEHIND the post shown at arrow put the smaller of the 2 wire down first then the larger one Stator bolts 3 5mmH 7 2 ft lb 86 4 inlb Pickup Coil bolts 2 4mmH 5 1 ft lb 61 2 inlb Be sure to run the stator wires as shown The rubber grommets should be positioned so the flat edge is face up Page 10 of 23 Now install the bracket Be careful not to pinch the wires Bracket bolt 1 4mmH 5 1 ft lb 61 2 inlb Put the NEW crankcase cover gasket in place on the engine Page 11 of 23 alternatorcover360 jpg starorwines3 60 jpg Install the Left crankcase cover Torque the bolts 14 5mmH 7 2 ft lb 86 4 inlb Be sure to torque the bolts evenly I typically use the same method as when you replace a car tire Do one bolt then the opposite bolt going in a clockwise direction Connect the new stato
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