2002 6th Gen Stator Issue

Discussion in 'General VFR Discussions' started by Frisco Kid, Jun 22, 2020.

  1. Frisco Kid

    Frisco Kid New Member

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    Hello world, So i've run into an issue and have searched and searched and look to your collective guidance. Yes, the manual is on its way but somehow has been lost in the mail twice!

    So, i have been plagued with a bad stator. Broke down several years ago ordered the parts from RMStator and placed it aside until I had the time. 2 years later I have the time. The tear down was simple enough. Cleaned her up and ready to replace only it didn't fit! After reviewing the measurements it appears the 2002 alternator cover (the base that holds the flywheel is smaller than a normal 6th Gen. Is it tru the 2002 6th Gen model has the body of a 2001 5th Gen?

    I'm a bit skeptical when attempting to order parts. RMStator said they have another replacement but the measurements they provided don't match. I've heard Rick's Stators are a good replacement but again the measurements don't add up and I don't want to replace the flywheel.

    Thank you in advance for your collective wisdom.

    - Frisco
     
  2. mello dude

    mello dude Administrator

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    RM stator=Rapid Melt stators.....
    Sorry can't answer the 2001 vs 2002 question.
    Really get OEM or call Custom Rewind in Alabama.
    The guy has MS, so you have to be a bit patient.
    He is by phone call only.

    You may as well do the whole job, and do the R/R too....

    www.roadstercycle.com

    I have mounting plate kits if you go that way.
     
    Last edited: Jun 22, 2020
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  3. rhoderage

    rhoderage New Member

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    02 stator is a different size than 03-09... there was a recall or TSB or something like that so some have been updated/replaced... I also have an 02 and have been holding off cracking it open until it goes because I don't know if i have the original or a replacement since I bought the bike used.
    The general recommendation for 02's has been to buy OEM or do a rewind with Custom Rewind as Mello Dude mentioned

    If you would post up the measurements of your alt cover and anything else that can help 02 owners with this [ie me :)] it would be appreciated!
     
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  4. Frisco Kid

    Frisco Kid New Member

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    Thanks all for the advice. RMStator is basically providing me a replacement. Im going to try the 5th Gen 01' as the written specs look closest. If that doesn't work then I will attempt to find OEM. It should arrive in a day or two. I will post pics of the measurements and provide feedback. I already replaced the R/R w/ a Mosfet (from RM Stator) but will most likely purchase a new one that has the metal backing and is Shindengen.

    I will also attempt to post how I wired the new stator. Currently I have a pull string but the stators end harness is large and wont pull through with ease unless I remove the housing for the air cleaner. What a pain... stay tuned!
     
  5. Frisco Kid

    Frisco Kid New Member

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    UPDATE: So i was able to get a Gen 5 Stator for my o2' Gen 6. It's actually a close match, the only problem is the rubber grommet is not the coreect size. So i will either need to remove the new leads and replace with the old grommet or need to purchase an OEM for $300 which no one seems to have. I've posted a few pics to show the difference between Stators.

    IMG_1995.jpg IMG_1996.jpg IMG_1997.jpg IMG_1998.jpg IMG_1999.jpg IMG_2001.jpg IMG_2003.jpg
     
  6. rhoderage

    rhoderage New Member

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    What a pain...exactly why I haven't touched mine yet. Conventional wisdom is replace with OEM, have you searched online parts catalogues and dealers and called some Honda dealerships as well?

    Perhaps a forum member may know their local Honda has some in stock and could let us know?

    Otherwise its back to Custom Rewind as the next best option...

    Curious though, how close is that rubber grommet? Could you trim it down to fit or is that not realistic due to shape?
     
  7. Frisco Kid

    Frisco Kid New Member

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    Yeah, thought of that... If i trimmed it down it would wreck the seal most likely. There is some type of silicone used on the old grommet, not sure what type, to seal the air gaps. I could use that as fill but I don't want to chance it by trimming it down.

    I called several local dealers and they have them, quoted me $450 not including tax! Most online stores don't have the OEM stator itself but they do have the set (stator w/ flywheel). In that option you can upgrade to a larger stator, meaning the one that most Gen 6's have. Moral of the story if you have an early Gen6 (meaning early 02') then you have the Gen 5 stator. And as mentioned above they sell it with the wrong grommet. So.... i will most likely cut the wires on the stator somewhere, use the old grommet, then butt splice it. Doing it this way will assist with rerouting the stator wire and maybe, just maybe I wont have to remove the air box. I'll let you know how it turns out
     
  8. mello dude

    mello dude Administrator

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    A rewind runs around $125......still a good option....
    Would ask for extra long leads.....
     
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  9. raYzerman

    raYzerman Member

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    The grommet is usually sealed with RTV gasket maker...... worst case you can split the original and replace it on the new stator, just clean it up well with isopropanol and "glue" it with RTV..... but smear RTV on the outside as well, and do all this as you put it together. The RTV will start to set up in half an hour and once installed will be just fine.
     
  10. Frisco Kid

    Frisco Kid New Member

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    That's a great idea! i'm going to try that instead of splicing. Thanks for the tip!
     
  11. rhoderage

    rhoderage New Member

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    So just buy a 5th gen stator, swap the grommet from 6g to 5g, use the RTV to reseal it to itself and the cover, and voila?

    Well thats good news!

    Are 5g stators any more reliable than 6g? Any good aftermarket ones or OEM recommended?
     
  12. Frisco Kid

    Frisco Kid New Member

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    I can't comment on reliability but I would assume it puts out more power but uncertain on the actual difference. I have read you can upgrade to the larger stator on earlier models (like mine) but you must replace the flywheel when doing so. I have found Honda and others do sell these as a kit (both stator & flywheel together). I don't want to replace my flywheel for the simple reason I'm not a mechanic and I don't want to risk damaging the crank case. I'm sure many on this forum will say it's simple I simply don't want to go down a rabbit hole.
     
  13. Frisco Kid

    Frisco Kid New Member

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    UPDATE: I was able to use the 5th Gen Stator on the o2'. (see pictures) Basically after thinking it through even thought the grommet was not the right size when you apply pressure it expands. I little RTV silicon around the edges and in between suggested by "raYzerman" solves the problem. When the alternator cover is sandwiched the grommet expands creating a seal. I'll let her sit overnight to cure then an oil change since the cover has been off for a bit. I painted the cover so she feels all pretty underneath. IMG_2046.jpg IMG_2046.jpg IMG_2047.jpg IMG_2049.jpg

    I decided since she was stripped to install the VFRness (https://www.wiremybike.com/product_info.php?products_id=266). pics below of how I routed it. Hope this takes care of some of the other problems. Hope this helps someone in the future.

    I decided to route under the chasis.

    IMG_2056.jpg IMG_2057.jpg IMG_2058.jpg
     
  14. rhoderage

    rhoderage New Member

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    Good call, I have the same setup (VFRness) and its been flawless. I replaced the RR with a Ricks from member Tightwad. Just waiting on the stator, I'm at ~60,000km but unknown if it was ever touched.

    So just to be clear, you used the grommet which came on the 5g stator, you didnt have to transfer the original 6g grommet?

    Thanks very much for doing the legwork on this, its truly appreciated.
     
  15. raYzerman

    raYzerman Member

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    Looking good. Good news on the grommet. If you're keeping the VFRness with those connectors, I'd look at them every year to ensure they are snug/tight not discolouring. If you are very careful, you can put a little Noalox or Oxgard contact paste in each terminal to promote contact/prevent oxidation, but don't cross-contaminate as to create any contact with the adjacent terminal in the connectors.
    I'd also recommend a voltmeter somewhere so you can monitor charge voltage as you ride, can see changes as you turn on accessories such as heated gear, heated seats, aux. lighting. If voltage drops significantly with no accessories on, then you need to look at connections again, etc.
     
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