GV650 Stator
My stator is burned and i am trying to find out why.
MOST COMMON FAILURES:
1) The stator can quit producing power usually due to the insulation failing. This is commonly caused by age or overheating.
2) The regulator/rectifier can have one or more rectifier diodes fail, which causes the output to drop to zero, or it can have the regulation circuit fail which causes the output voltage to be unregulated and liable to climb past 16Vdc.
Magneto Assembly
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| GV650 Stator, Magneto Assembly |
1 32100HN9101
MAGNETO ASSEMBLY $212.76
2 32101HN9101
2 32101HN9101
STATOR ASS'Y, (ALL 650's) SAME AS 32101HP9300 $148.75
3 32102HN9100
3 32102HN9100
ROTOR, FLY WHEEL $141.28
4 02142-05128
4 02142-05128
SCREW $0.65
5 07110-06308
5 07110-06308
BOLT, M5x30 $0.65
6 09103H12001
6 09103H12001
BOLT, MAGNETO (GV & GT 650) $3.93
7 09420H04001
7 09420H04001
KEY, MAGNETO $1.17
8 09160H12003
8 09160H12003
WASHER $2.22
electrosport.com ESG110
www.electrosport.com
Step 1
Disconnect the original stator wires emerging from the wiring loom. Unscrew the bolts that hold the engine cover in which the stator is mounted. Then take the cover off.
Step 2
If the cover is tight, use a rubber hammer to tap on the sides. Never use a screwdriver in between the joining surfaces. Sometimes you will need to get another cover off to release the original stator leads from the engine.
Step 3
Unscrew the three or four screws that hold the stator inside the cover. These can be a tight fit. Be careful not to damage the cover when using an impact screwdriver to loosen the screws. Also, unscrew all wiring holding clips which may be inside the cover.
Step 4
Look for the rubber grommet that is along the wiring harness. The three leads run through this. Cut the wires close to this grommet and pull the wires out. If you have difficulties getting the wires out, hold the grommet in hot water for a few seconds. The wires should then come out easily.
Step 5
Feed the new stator wires through the holes in the original grommet. Use the plastic sleeving supplied with the new stator to run the rest of the wires through. Connect the bullet connectors of the connector block to the end of the wires. Make sure you have good connections here. If in doubt, solder the new connectors to the wires. Note: When fitting a connector block, first connect the copper clips to the wires and then slide the clips into the plastic connector block.
Step 6
Mount the new stator inside the engine cover. Make sure you tighten the screws carefully. Use locking compound on the threads of the screws. The same goes for the clips that hold the wiring inside the cover.
Step 7
Make sure the grommet is in the correct position when you refit the engine cover. Also, use a new gasket to make sure it won’t leak oil.
Step 8
Check if the engine rotates freely. Then tighten the bolts that hold the engine cover.
Step 9
Connect the stator wires to the wiring loom. Note: on older Suzuki’s the wires from the stator have three different colors. This is intentionally done to cause confusion, but the output of all wires is the same. The new replacement stator has three yellow or white output wires.
Step 10
Start the engine and test if the charging system is working.
Note:
If any powder coating on the stator has a chip in it, technically it does not make a difference in the performance or operation of the part. The color Epoxy finish is for decoration only. The electrical wire insulation underneath the Epoxy is clear colored and invisible to
GV650 Regulator / GV650 Rectifier
 |
| 32101HN9101 The Stator |
32101HN9101
32101HP9300
- ragingparts.com $165.95
- hyosungparts.asia $122.00
- hyosungsource.com €88.54
- koreanbikeparts.com $110.85
Stator OEM Replacement
Stator Kawasaki EL / EN / EX models
Kawasaki models between the years 1985 and 2009
EX250 Ninja, EX500 Ninja, GPZ500, EL454, EL500, EN500
 |
| GV650 Stator Replacement ESG110 |
| Core Thickness | Output (A) @1000rpm | 1200rpm | 1400rpm | 1600rpm | 2500rpm | 3600rpm | 6000rpm | Power(W)@13Vdc | |
|---|---|---|---|---|---|---|---|---|---|
| EX250 Stator (stock) | 13mm | 6 | 8 | 10 | 11 | 13 | 14 | 15 | 180W |
| ESG110 Stator | 15mm | 6 | 10 | 12 | 14 | 17 | 18 | 19 | 230W |
Description
ESG110 is a high quality stator that replaces the OEM stator in the
Kawasaki EX250 Ninja, EX500 Ninja, GPZ500, EL454, EL500 and EN500 models
between the years 1985 and 2009
ElectroSport manufactures the ESG110 stator starting with a brand new
stator core made of special material that has very low magnetic
resistance. We use the highest grade copper wire for the windings which
are installed using computer controlled winding machines for optimum
results.
Our lead wires are of very high quality and we chose a type that is
abrasion and heat resistant. The rubber seals and connectors are an
exact match for the original stator making this ESG110 a plug in
replacement.
With the top notch materials and design features chosen our ESG110 stator offers superior performance and reliability.
Like all stators manufactured by ElectroSport this ESG110 stator also comes with a full one year warranty
 |
| GV650 Stator Replacement ESG110 |
 |
| GV650 Stator Comparison |
 |
| GV650 Stator Replacement ESG110 |
 |
| GV650 Stator Comparison |
- Ouside Diameter is the same
- Inside diameter is the same
- Screw holes are the same
- Hight is NOT the same. OEM is higher than the replacement.
- Cable is NOT the same. OEM cable is needed!
ESG 3 PHASE Stator - Fitting
Applications: Universalwww.electrosport.com
Step 1
Disconnect the original stator wires emerging from the wiring loom. Unscrew the bolts that hold the engine cover in which the stator is mounted. Then take the cover off.
Step 2
If the cover is tight, use a rubber hammer to tap on the sides. Never use a screwdriver in between the joining surfaces. Sometimes you will need to get another cover off to release the original stator leads from the engine.
Step 3
Unscrew the three or four screws that hold the stator inside the cover. These can be a tight fit. Be careful not to damage the cover when using an impact screwdriver to loosen the screws. Also, unscrew all wiring holding clips which may be inside the cover.
Step 4
Look for the rubber grommet that is along the wiring harness. The three leads run through this. Cut the wires close to this grommet and pull the wires out. If you have difficulties getting the wires out, hold the grommet in hot water for a few seconds. The wires should then come out easily.
Step 5
Feed the new stator wires through the holes in the original grommet. Use the plastic sleeving supplied with the new stator to run the rest of the wires through. Connect the bullet connectors of the connector block to the end of the wires. Make sure you have good connections here. If in doubt, solder the new connectors to the wires. Note: When fitting a connector block, first connect the copper clips to the wires and then slide the clips into the plastic connector block.
Step 6
Mount the new stator inside the engine cover. Make sure you tighten the screws carefully. Use locking compound on the threads of the screws. The same goes for the clips that hold the wiring inside the cover.
Step 7
Make sure the grommet is in the correct position when you refit the engine cover. Also, use a new gasket to make sure it won’t leak oil.
Step 8
Check if the engine rotates freely. Then tighten the bolts that hold the engine cover.
Step 9
Connect the stator wires to the wiring loom. Note: on older Suzuki’s the wires from the stator have three different colors. This is intentionally done to cause confusion, but the output of all wires is the same. The new replacement stator has three yellow or white output wires.
Step 10
Start the engine and test if the charging system is working.
Note:
If any powder coating on the stator has a chip in it, technically it does not make a difference in the performance or operation of the part. The color Epoxy finish is for decoration only. The electrical wire insulation underneath the Epoxy is clear colored and invisible to
GV650 Regulator / GV650 Rectifier
Shindengen FH012AA Regulator / Rectifier
NOTE, if you are having issues at all with your charging system, do this upgrade. The bike is running so much better. At idle, I get 13.8 volts off the battery. At 2500 RPM I am getting 14.4 Volts off the battery. Others who have done this upgrade state this upgrade allows them to mount horns, extra lights, and other electrical components with no effect on the battery or the charging system. The MOSFET FH012AA RR provides a lot more juice and amperage to work with.
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| GV650 OEM Voltage Regulator |
 |
| GV650 OEM Voltage Regulator |
OEM Voltage Regulator Rectifier Hyosung $82.12
32800HN9110 GV650 Carb Models
OEM stator replaced
Links on articles from people who have replaced their OEM stator with another
EX250 or EX500 stator 1992 through 2000
motoelectro.gr
motoelectro.gr
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