1. Introduction
This manual provides essential information for the installation, operation, and maintenance of your new aftermarket Motorcycle Stator Coil, Model XQ-568. This high-quality and durable replacement part is designed to meet or exceed OEM specifications, ensuring reliable performance for your motorcycle's electrical system.
Compatibility:
- For OEM Part Numbers: 31120-HE0-003, 31120-HE0-013
- For Honda FL400 FL400R (1989-1990 models)
2. Safety Information
Always prioritize safety when working on your motorcycle. Improper installation or handling of electrical components can lead to serious injury or damage to your vehicle. If you are unsure about any step, consult a qualified motorcycle mechanic.
- Always disconnect the motorcycle's battery (negative terminal first) before beginning any electrical work.
- Wear appropriate personal protective equipment, including safety glasses and gloves.
- Ensure the motorcycle is stable and securely supported before working on it.
- Avoid touching hot engine components.
- Keep all tools and parts clean and free of debris.
3. Package Contents
Upon opening your package, please verify that all components are present and undamaged:
- 1 x Motorcycle Stator Coil Assembly (including main coil, wiring harness, and pickup coil)
Figure 3.1: Overall view of the Motorcycle Stator Coil, including the main coil assembly, wiring harness, and pickup coil.
4. Specifications
| Feature | Specification |
|---|---|
| Model Name | XQ-568 |
| OEM Part Numbers | 31120-HE0-003, 31120-HE0-013 |
| Compatibility | Honda FL400 FL400R (1989-1990) |
| Condition | Aftermarket 100% Brand New |
| Item Weight | 0.8 kg |
| Package Dimensions (L x W x H) | 10 cm x 10 cm x 5 cm |
5. Installation (Setup)
The stator coil is a critical component of your motorcycle's charging and ignition system. Proper installation is crucial for optimal performance. Refer to your motorcycle's service manual for specific torque values and detailed disassembly/assembly procedures.
General Installation Steps:
- Preparation: Ensure the motorcycle is cool. Disconnect the battery's negative terminal. Drain the engine oil if the stator is located behind the engine cover that requires oil removal.
- Access the Stator: Remove the necessary covers (e.g., left crankcase cover) to gain access to the old stator coil. Carefully remove any gaskets or sealant.
- Disconnect Wiring: Trace the stator's wiring harness to its connectors. Disconnect the main electrical connector (Figure 5.1) and any secondary connectors, such as for the pickup coil (Figure 5.2). Note the routing of the wires.
- Remove Old Stator: Unscrew the mounting bolts holding the old stator coil in place. Carefully remove the old stator and its associated pickup coil (Figure 5.3).
- Install New Stator: Position the new stator coil (Figure 5.4) and pickup coil in their respective locations. Ensure the mounting holes align correctly (Figure 5.5). Secure with the original mounting bolts, applying thread-locking compound if recommended by your service manual, and torque to specifications.
- Connect Wiring: Route the new wiring harness exactly as the old one was routed to prevent chafing or damage. Connect all electrical connectors securely.
- Reassemble: Install a new gasket for the engine cover (if applicable) and reattach the cover. Refill engine oil if drained.
- Final Checks: Reconnect the battery (positive terminal first, then negative). Start the motorcycle and check for proper charging system operation (e.g., battery voltage at idle and higher RPMs).
Figure 5.1: Main electrical connector.
Figure 5.2: Secondary electrical connector.
Figure 5.3: Pickup coil component.
Figure 5.4: Rear view of the new stator coil.
Figure 5.5: Stator coil mounting holes.
6. Operating Principles
The stator coil is a stationary part of the motorcycle's alternator system. As the engine runs, the rotating flywheel (rotor) with its magnets passes over the stator's copper windings. This induces an alternating current (AC) in the stator coils. This AC current is then sent to the voltage regulator/rectifier, which converts it into direct current (DC) and regulates the voltage to charge the battery and power the motorcycle's electrical components.
7. Maintenance
While the stator coil itself requires minimal direct maintenance, regular inspection of the charging system can prolong its life and prevent issues:
- Visual Inspection: Periodically inspect the stator wiring harness for signs of chafing, cracks, or heat damage. Ensure all connectors are clean and securely seated.
- Battery Health: A healthy battery is crucial for the charging system. Ensure your battery is properly maintained and holds a charge.
- Voltage Regulator/Rectifier: A faulty voltage regulator/rectifier can overcharge or undercharge the battery, potentially damaging the stator. Ensure this component is functioning correctly.
8. Troubleshooting
If you experience electrical issues after installing the new stator, consider the following common problems and solutions:
Common Symptoms of Stator or Charging System Failure:
- Battery not charging (low voltage reading while engine is running).
- Weak or flickering headlights/dashboard lights.
- Motorcycle dies while riding.
- Engine misfires or runs poorly (can be related to ignition system issues, which the stator also supports).
Troubleshooting Steps:
- Check Battery: Ensure the battery is fully charged and in good condition.
- Inspect Connections: Verify all electrical connections related to the stator and regulator/rectifier are clean, tight, and free of corrosion.
- Test Stator Output (AC Voltage): With the engine running at specified RPMs (refer to your service manual), measure the AC voltage output from the stator's output wires (usually three yellow wires). Readings should be consistent across all phases.
- Test Stator Resistance: With the engine off and stator disconnected, measure the resistance between each of the stator's output wires. Readings should be very low and consistent. Also, check for continuity between any stator wire and ground; there should be no continuity.
- Test Voltage Regulator/Rectifier: A faulty regulator/rectifier can mimic stator problems. Test this component according to your motorcycle's service manual.
9. User Tips
- Verify Compatibility: Always double-check the OEM part numbers and motorcycle model/year to ensure correct fitment before purchasing and installing any replacement part.
- Consider Related Components: When replacing a stator, it is often recommended to inspect or replace the voltage regulator/rectifier as well. A failing regulator can cause a new stator to fail prematurely.
- Use a Service Manual: For detailed, model-specific instructions, torque specifications, and advanced troubleshooting, always refer to your motorcycle's official service manual.
10. Warranty and Support
For any questions regarding this product, including warranty claims or technical assistance, please contact the seller directly through the platform where the purchase was made. Keep your purchase records for reference.
