How do you replace the stator on a 1987 Yamaha virago 535 Yamaha?

Answer 1

I just replaced the stator on a 1993 750 Virago. The procedure should be about the same with the 535. You have to drain the oil or lean the bike to the right and support it so that the oil does not spill out when you remove the left side engine cover. Disconnect all electrical coming out of the left side engine cover. Remove all the bolts on the left engine cover. Make sure to stick the bolts in a cardboard in the order you remove them as they are not all the same lenght. Tap the side cover loose with a mallet and try to save the gasket if you can. The stator is bolted to the inside of the engine cover with Phillips bolts. You need an impact driver to loosen these. Careful not to damage the slots. (I replaced mine with Allen bolts). New stator are about $125, Used less than $50. I live in the Philippines and I had mine rewired (rewind) for less tha $20.

If the gasket breaks, make one with belumoid or gasket material .50mm thickness. I clean the lip of the engine cover, apply rubber cement to it and to the gasket material and stick them together. With an Exacto knife, cut the holes first then the rest of the gasket material. Almost as good as the factory gasket. When you apply it to the engine case, apply a thin coating of grease so that if ever you remove it again, the gasket does not stick to the engine case.

It is not hard, just messy.