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These are the steps I took to replace my stator and may not be exactly the way you’d do it but might help someone else to do theirs. So, if they aren’t what you expect I don’t wanna hear about how I screwed up. If you have anything good to add please do, just don’t be a dick!


Step 1. Go buy gaskets for starter cover and left crank case cover. They should only run about $15 for both. Oh, and oil too!
Step 2. Go buy beer for buddy that is going to be helping you. :beer:
Step 3. Pump up tires to make it easier to move quad.

Step 4. Drain oil.
Step 5. Take off seat to get to the bolt that is to the left of your gas tank that holds on your plastics and remove it.

Step 6. Pull back the plastic on left side of your quad and you’ll see the two plugs for your stator to unplug. Just don’t pull too hard and break it. I know someone will probably say this is incorrect and tell you to take off all your plastics but this is the way I did it and it worked fine. If you’re worried about it go ahead and take off all the plastics.

Step 7. Remove bolts on starter cover. Remember that some bolts may be longer than others and in this case there is. I marked the bolt that is longer in this picture.

Step 8. Remove starter cover. If it don’t just pull off use a rubber mallet to break it loose. Be careful when taking this off because there is a gear in here that could fall out when removing cover. If it doesn’t fall out when removing the cover, pull this gear out. The upper gear will not have to come off.

Step 9. Get a piece of paper and trace around your gasket so you can put your bolts you take out of the case on the paper to remind you of where all the different bolts go. This isn’t something you need to do but it’s something I do just to make sure things go back where they’re supposed to.

Step 10. Take out bolts on case cover. Most of the bolts are pretty easy to get to but there are two that require a little more effort. The bottom bolt and the one left of it. We used a deep socket to get to the bottom one because I didn’t want to stand it on end and take off the skid plate. It worked pretty well this way because the deep socket held up the oil line for us. You can pry on these a little but be careful.


Step 11. Use a rubber mallet to hit the cover with and break it loose and pull the cover off. The cover was a little hard to get off because the starter has an O ring that is holding it on, keep working it though and it will come off. Once off check for these two little rubber O rings if they aren’t on the cover they might still be on the case. The little metal posts that these rings go around may fall out or can be pulled out with a little bit of effort and makes it a lot easier to remove the old gasket later. We didn’t have to remove the gear shifter to pull this cover but, if you feel like it will be easier have fun!


Step 12. Remove this gear and remember that the big side goes down when putting it back. Then remove the bracket that is holding your wires down.

Step 13. Remove stator and pickup coil. These bolts all have high heat lock tight on them and should have it put back on when re-installing. Because of the lock tight when removing these bolts can be a little tough to remove and feel kind of like they are stripping. Just be careful and you should be fine. Remember what holes the bolts will go back in. Then put new stator in. Remember what way the pick up coil goes back in.

Step 14. Go to autozone get cheap die grinder :mad:, buy buddy lunch, and hit the liqueur store.

Step 15. Come home and get in trouble for not calling and asking girlfriend if she wants anything to eat. :slap:
Step 16. Use a razor blade to take off most of old gasket from cover and then use die grinder to take off the rest. Remove any pieces of old gasket on case as well.
Step 17. Use a little automotive silicone to go around the cover to hold your gasket and O rings to the cover, then replace it back on the case and get to putting everything back to how you took it apart.
Step 18. Replace oil.
Step 19. GO RIDE! :thumbsup:

Sorry if I might have missed anything this was a lot to do and might have missed it. Hope this helps somebody.
 

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Step 9 is one of the best ideas i have Ever seen :thumbsup:
 

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Discussion Starter #3
Cool! Thanks, and hope this will help you.
 

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Nice writeup :thumbsup:
 

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nice
this will help the other members
good job :thumbsup:
 

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when i did my clutch i pressed the bolts through cardboard to remember where the went.
 

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Master of the Electron
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So you buy the die grinder just because you have an excuse to increase your tool inventory while hiding the fact that you don't really need it for this job from the girlfriend/wife? Brilliant!
 

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Discussion Starter #10
Where the hell did all my pics go?
 

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Whats a Stator? Im a NOOB! ???
 

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kylegentz said:
Whats a Stator? Im a NOOB! ???
stator is what generates electricity. On the crankshaft opposite side from the clutch. Check out the pics above.


Oh....wait "use the search feature" There! now you've got your required newbie reply. :lol:
Could have got a rickroll link too. :grin_nod:

How is it you don't know a stator and you have all those mods in your sig? Did ya buy it that way?
 

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lol, No actually all the mods i have done, the Big bore on the 01 was done due to a scratched piston, i put the stage 2 cam in, that was easy and it came with ported and polished heads, The 02 had all bolt ons basically besides jets and pipe. I know some from what my dad has tought me but he only knows old cars and these new motorcycle/ATV aluminum motors kinda confuse him.:brick: Thats why i am hear to learn and help (the little i do) any way i can!

-kyle
 

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this is the best place to learn! :thumbsup: I was lurker here for a month before I decided to buy my 01. Anything you need can be found.
 

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My stator just went out and was wondering what is the best brand and where can I get the best deal?
 

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First make sure your battery is still good, it wont charge if it is shorting out or just junk. If the battery is in good condition you need to check the wiring running from the stator up through or if you can find the numbers you can test the stator. Stators dont usually fail and im pretty sure the ATV wont run if the stator fails because the battery is only used to start it and all the power for sparking and other stuff is generated from the stator.
 

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come and do mine for me, i will buy you beer and let you have a go on the wife !!!!!!!!!!!!!!!!
 
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