PLEASE HELP Stator coil, magneto flywheel dimensions

Discussion in 'Mechanics Garage' started by Natty B, Sep 9, 2021.

  1. Natty B

    Natty B New Member

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    Ok, this is the third time writing all of this as it keeps friggin not uploading and wiping all my text.

    PLEASE HELP!

    I want to know the factory ID of the magneto flywheel and the OD if the factory stator coil.

    I fixed a previous owners botchy Frankenstein job of the charging system, i.e different Rectifier/regulator, wired independently from the loom.

    I've gone to install the regular OEM type stator coil, it OD is 115 mm and ID of the magneto flywheel is 110mm.

    What I am wanting to know is the OEM dimensions of both these components?

    Has the turkey who changed the charging setup, also changed the flywheel and stator coil size from the original?

    Please help as it's infuriated me that someone would mess with the OEM charging system.

    I have OEM parts that won't fit where they are supposed to. There is a slim chance the supplier sent the incorrect part, but that is rather unlikely.
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  2. Diving Pete

    Diving Pete Member

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    it may be more helpful to tell us the model & year please..
     
  3. Natty B

    Natty B New Member

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    Hey Diving Pete,

    Year of my bike is 2002-03 VFR800A2 ABS 6th gen
     
  4. Natty B

    Natty B New Member

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    The stator coil that came out is 107mm.
    Inside of the 110mm magneto flywheel.

    The new stator is 115mm
     
  5. Natty B

    Natty B New Member

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    The model is 2002 VFR800A2 ABS 6TH Gen
     
  6. rhoderage

    rhoderage New Member

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    2002 is a tricky one... i have one as well. original oem stator was noted as not powerful enough to keep the system charging properly, so honda did an update/recall for a larger stator. recall ended in 07, i purchased my 02 in 2012 or so... no punch mark on the vin tag so i assume mine is still original. i have a vfrness and ricks r/r installed (*8 years now, no problems, if i did it again i'd buy the roadstercycle kit based on reviews) and a voltage monitor which shows a rock steady 14.3v while running

    the crummy thing is that its very hard to find a non-oem 2002 stator... the aftermarket ones seem to all be labeled 2003+, and I havent had to get into mine yet to see whether i still have the original or if a PO had changed it in years before i owned the bike. 2003+ came with the upgraded part

    what i intend to do if mine goes, or if i get ambitious over the winter, is to pull the oem stator and send to CUSTOM REWIND for exactly that, a rewind. The shop has great reviews from VFR owners... this way at least (if you are starting with oem part) you know its the right fit

    your pic above looks like a new stator. the gasket goop on top of the green gasket paper is not oem, oem was just the green gasket paper... so yeah someone has been in there. since you have the '02 call it 50% odds whether its the right or wrong part

    ugh i can't seem to attach a pdf so i'll cut and paste the wording from the recall below ***EDIT looks like the pdf did attach below, all good

    please do keep updated as you resolve this, as i continue to be interested in anyone with an 02 finding a replacement that actually fits and works, and if they still have the original flywheel or the upgraded parts at the time

    2002 VFR800/A
    Product Update Campaign
    AC Generator

    American Honda's Motorcycle Division is conducting
    a Product Update Campaign to replace
    2002 VFR800/A alternator assemblies that may
    produce inadequate output during certain riding
    conditions.
    Some 2002 VFR800/A customers may complain
    about frequent battery discharge or the starter’s
    inability to crank the engine. These conditions
    may occur if the high beam and radiator fan are
    both in operation when riding at low engine
    speeds or idling for an extended period of time.
    To improve charging system performance under
    these conditions, a new, higher output alternator
    is now available.
    AFFECTED UNITS

    All 2002 VFR800/A models
    Follow the INSPECTION, UPDATE, and IDENTIFICATION
    procedures in this bulletin.
    CUSTOMER NOTIFICATION
    American Honda is sending a letter to owners of
    all 2002 model year VFR800/As, informing them
    that they are entitled to receive this update at no
    cost. They will be instructed to call and make an
    appointment to have the update performed. For
    your reference, the text of the customer letter is
    reproduced on page 4 of this bulletin.

    INSPECTION
    Before you begin the update, check for a punch
    mark at the beginning of the VIN on the frame.
    (see IDENTIFICATION section on page 3).
    If there is a punch mark, the unit has been
    updated and no further action is necessary.
    If there is no punch mark, follow the UPDATE
    PROCEDURE.
    UPDATE PROCEDURE
    1. Remove the side cowls (Service Manual,
    pages 2-8 and 2-9). Do not remove the inner
    half cowl.
    2. Remove the radiator reserve tank mounting
    bolts (Service Manual, page 6-17). Secure the
    reserve tank to the frame with a suitable piece
    of wire or twine. Be careful not to spill any
    coolant.
    3. Disconnect
    the alternator 3P connector and
    cut the connector wires at the location shown
    4. Securely tie and tape the cut end of the
    alternator wire to a minimum 75 cm (30 in.)
    length of durable wire or twine. Carefully pull
    the cut wire through to the alternator side and
    detach from the wire or twine. Leave the wire
    or twine in place until Step 9.
    5. Place a clean drain pan under the alternator
    to capture any oil that may drain out when
    removing the alternator. Disconnect the 4
    wire harness connectors below the alternator
    cover, then remove the cover, stator, and flywheel
    (Service Manual, pages 17-10 through
    17-12). Do not remove the throttle body.
    Discard the 6 x 38 mm torx bolts securing the
    stator.
    6.
    Install the new stator into the alternator cover
    using the 6 x 34 mm bolts provided in the kit
    (Service Manual, page 17-11). Torque the
    bolts.
    TORQUE: 12 N•m (1.2 kgf•m, 9 lbf•ft)
    7. Install the new flywheel (Service Manual,
    page 17-12). Torque the bolt.
    TORQUE: 103 N•m (10.5 kgf•m, 76 lbf•ft)
    8. Reinstall the alternator cover and new gasket
    (Service Manual, pages 17-12 and 17-13).
    9. Secure the wire or twine passed through the
    frame in Step 4 to the connector of the new
    alternator wire. Then, wrap the connector
    with tape to prevent damage to the connector
    locking tab.
    Carefully pull the wire or twine through to the
    right side of the
    motorcycle and connect the
    3P connector.
    If the 3P connector gets caught while being
    pulled through to the right side, use a flashlight
    and flat-blade screwdriver to carefully
    guide the connector.
    10. Reconnect the 4 wire harness connectors
    below the alternator cover. Reinstall the radiator
    reserve tank in the reverse order of
    removal (Service Manual, page 6-17).
    11. Reinstall the side cowls in the reverse order
    of removal (Service Manual, pages 2-8 and
    2-9).
    12. Measure and add any engine oil that may
    have drained out during alternator removal.
    13. Start the engine and allow it to warm to normal
    operating temperature. Adjust the idle
    speed using the throttle stop screw.
    Idle speed: 1,200 + 100 rpm
    PARTS INFORMATION
    You do not need to order this kit. Initial parts kits
    will be automatically allocated by American
    Honda based on the number of units invoiced to
    your dealership. You will be notified when kits are
    available for open ordering.
    Set, AC Generator Kit:
    P/N: 31100-MCW-305
    H/C: 7338734
    (this kit includes all parts necessary to perform
    this Product Update)
    • Flywheel
    • Stator
    • Gasket
    • Socket bolt
    • Sealing washer (not needed - do not use)
    WARRANTY INFORMATION
    This Product Update Campaign will end on
    October 17, 2007.
    Normal warranty claim submission requirements
    apply. Submit one warranty claim per VIN with
    the following information only:
    Template: L70A
    Hours: 1.8
    Parts: 31100-MCW-305

    TEXT OF CUSTOMER LETTER
    October 2002
    Dear 2002 VFR800/A Owner:
    RE: Product Update Campaign
    American Honda's Motorcycle Division is conducting a Product Update Campaign to replace 2002
    VFR800/A alternator assemblies that may produce inadequate output during certain riding
    conditions. Our records indicate that you own one of these motorcycles.
    Frequent battery discharge or the starter’s inability to crank the engine may occur if the high beam
    and radiator fan are both in operation when riding at low engine speeds or idling for an extended
    period of time. To improve charging system performance under these conditions, a new, higher
    output alternator is now available.
    Please contact your nearest authorized Honda motorcycle dealer and make an appointment to
    have the alternator assembly inspected and replaced. The dealer will replace the parts at no cost
    to you. Please plan to leave your motorcycle at the dealer for at least half a day to allow for dealer
    scheduling.
    This Product Update Campaign ends October 17, 2007. You must have your VFR800/A
    updated prior to this date; after this date your motorcycle will no longer be eligible to have this
    update performed free of charge.
    As this update also applies to subsequent
    owners, please keep this letter with the Owner’s Manual.
    If you have moved or no longer own your 2002 VFR800/A, please take a moment to complete and
    mail the enclosed Information Change Card so we can update our records.
    You may visit our website at www.hondamotorcycles.com and click on “locate a dealer” to find a
    dealer who can assist you. Should you need assistance locating a dealer or have questions about
    this campaign, please call Motorcycle Customer Support at (310) 532-9811.
    If you have previously paid for the replacement of the alternator assembly or battery, contact your
    Honda dealer for reimbursement information.
    We apologize for any inconvenience this may cause you.
    Thank you for your VFR800/A purchase.



    ***hope this helps, pls keep us updated.
     

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  7. Natty B

    Natty B New Member

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    Hi mate, thanks for the info. I've been flat out until today, but also busy all weekend.

    I will go through everything on my bike that you have posted.

    Hopefully this will answer a load of questions I have.

    I really appreciate your help so far.

    Kindest regards,
    Natty
     
  8. Natty B

    Natty B New Member

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    Hi, thanks again for your reply.

    I have been able to track down the owner from almost 10 years ago.

    He only changed the R/R. He had wired it independently from the loom and had added a 12v 30Amps circuit breaker in line with the positive.

    The stator and magneto flywheel are the updated version honda replaced the original with.

    The original stator was 115mm and the flywheel was 118mm.

    The update from the recall was a 110mm flywheel with a 107mm stator coil.

    I am picking up a 107mm stator coil during the week and referencing it directly with the parts o have pulled off the bike, in the parts store.

    If I have any issues with it burning out or over heating, I will have to get the aftermarket kit that i have just pulled off.
     
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