How to Install a Stator

Installation of a stator assembly typically impacts motorcycles and scooters, which utilize the design attached to the crankshaft to generate electricity for lighting systems. While the installation itself is not highly technical or difficult, care needs to be taken that the steps are followed correctly. Otherwise the charging system will not work properly, and the installation will have to be repeated to correct the problem.

Instructions

Take the wires coming off the stator assembly and carefully wind them together so they form a "rope" of sorts. Gently insert this wiring rope through the engine case stator cavity so that the wires stick out of the engine correctly to connect to the electrical system.

Position the stator plate so that the flat plate side faces the engine case. Insert the exposed crankshaft arm sticking out of the engine through the hole in the middle of the stator plate. Press the plate into place in the pre-cast slots on the engine case side.

Insert the securing screws into the stator assembly. Tighten them with a screwdriver so the plate connects to the engine case via the pre-threaded screw cavities in the stator's case position. Don't fully tighten the screws yet.

Look for the timing mark on the engine case that is pre-cast in the case body. Line up the timing mark on the stator with the engine case timing mark. Use a timing dial and a top dead center gauge to determine correct timing per your engine manual, if your stator is not electronic. Use a flathead screwdriver to adjust the ignition points on the stator assembly for your engine manual's timing recommendation.

Tighten the securing screws to hand-tightness once the stator is in position. Do not over-tighten or you can strip the case threads.

Insert the woodruff key --- a metal position tab --- onto the crankshaft arm in the arm's slot. Position the flywheel onto the crankshaft and the woodruff key so that they line up with the hole and slot in the flywheel. Push the flywheel in and over the stator plate.

Tighten the flywheel down with a socket wrench and socket while using a flywheel holder to keep the flywheel in place rather than spinning.

Complete the engine assembly and start the engine. Check the engine performance to make sure that the engine is not pre-igniting or stalling because spark plug firing that occurs too early or too late. Reverse and repeat Steps 2 through 6 until the timing is correct if there are problems.