Kawasaki Vulcan VN750 stator replacement without removing the engine

Kawasaki Vulcan VN750 stator replacement without removing the engine
Update: 4-25-2017 The stator I put in for this video lasted for fewer than 3,000 miles before it grounded out. I replaced it again from the same supplier but this time I replaced the regulator with a new oem part and remounted it out in the air near the rear tire. That stator failed today, after 3,020 miles. I suppose I’m going to have to pay 0 for an oem stator, the original lasted 22,400 miles. My previous 1999 VN 750 had it’s first (oem) stator failure at 28,500 miles. The replacement for that (not oem) lasted 12,000 miles.

The suppliers for this project are listed below….click on Show More. Watch at 480p for best quality.

Replacing the stator (which failed at 20,400 miles) in my 2004 Kawasaki Vulcan VN750 motorcycle, without removing the engine from the frame.

Previous to this bike, I owned a 1999 VN750 and the oem stator failed after 28,500 miles. I replaced it by pulling the engine from the frame and used an new aftermarket stator. That stator failed after only another 12,000 miles. I don’t remember from whom I bought that stator. I replaced that one by pulling the engine also.

Suppliers for this project:

FEL Pro gasket material 1/8 inch thick, 10 inch x 26 inch sheet cork-rubber NAPA # FPG 3019

stator mod plate: GC-EXTREME Web Design & Graphics, http://www.gcextreme.com/shop/index.php?route=product/search&search=stator%20plate

Stator rewinding service: TPE Rebuilding Services, http://www.tpe-usa.com/

Update, added on 6-6-2015:
1,500 miles after this repair….all is well, no problems.

21 thoughts on “Kawasaki Vulcan VN750 stator replacement without removing the engine

  1. i had changed the alternator on my vulcan and was pissed off with having to remove the engiene ,,i tough of chopping off the bottom frame and bollt it back just as the opposite side ,,i  think this would have been easier to do than removing the engiene ,,

  2. After owning it for a week, I think that I need a new stator on my 2005 vn750. I am no mechanic and am terrified to remove/INSTALL!!! the entire engine and nearly all other assemblies. I am considering this stator mod. Where did you order that machined plate? Am I able to purchase one from the same place?

  3. Mine is a 1990 Vulcan 750.  I am also i need of the machined plate. I like this mod, but will have my mechanic do work.  Where can the plate be ordered? Thank you in advance for your help.

  4. How is the cork gasket holding up? I did this to my bike last year. The high temp rtv sealant I used leaks a bit.

  5. You’re a good guy. Really nice video. Hope the bike is till going. I have a 91 750 and an 08 VN900.

  6. very nice job Mr. Harv. I am much like yourself and pretty mechanical…I will attempt this mod next week. Good Job.

  7. I purchased the grinder at Harbor Freight Tools, about $25. For the bit I used a 1/8 inch drill bit, as it got dull I would cut off the dull end.

  8. That looks like a lot of bs work for nothin. it took you 4 hours to rip it apart. I did one the factory way, removing the engine yesterday and it only took me 2 hours to rip it apart and pull the stator. So why do it this way…..?

  9. Thanks for your adviser, I have a Kawasaki Vulcan VZ 750 1986 and now I need to do the same and follow your instructions by the video, I need ask one question if you have a chance to answer, after you replace the stator how was or is the indication of volts after you tour on the high light with the engine on and reading when the engine if off, I need to know how low is both cases.. , Im very far and is any chance to cut the plate in other place fallow with the dimensions……. thanks again

  10. Hi, have you done a video on how to replace the rectifier? I think I’ll do this mod on my Vulcan but I want to replace the rectifier as well. My mechanic wants to charge me about $2000 to replace this part. I’ve mentioned this method to him but he refuses to do it, instead he wants to remove the entire engine from the bike. My ONLY concern about doing it that way is if the stator fails again the engine will have to come out again. I’m a female and I just want to become independent, so I don’t have to rely on men. Thanks!

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