What stator will work?

I have a 81 KZ 550a wire harness on my 77 KZ 650B. To energize the generator I have a switch that excites the feild going to the generator.
I have a permanent magnet flywheel from a 750 GPZ that I want to put on the KZ 650.
Question is: Will a 550 stator work with the GPZ flywheel and still be able to mount on the 650 cover? Or will I need a cover too?
Is there a higher output stator I can use other then stock?

Will a KZ750 stator out of a LTD 1981 work?

if 750 GPZ you can use 1981 to 83 650 csr / kz 750 1980 TO 1983 750 standerd -4 (80-81)/ 750 LTD 80-81 / 750 std. 82 / 750 ltd 81/ std. 82 / ltd shaft 1983 / LTD 4 82-83/ sport 83 / spectra 82-83 / 750 GPZ 1982 all these interchange hope this helps but only for the 750 . all 550 will interchange only with 550 1981 to 1984 and also zr550b1 1990 and 1991 these also will work on your 550

It appears that what you are trying to do is upgrade your charging system while using the stock 550 plugs on the harness, correct?

Simple answer, use a 78 or later 650 (or 750 four) stator and splice the 550 wiring harness plug onto it. Actually, the later stators may even share the same plug as the 550, no way for me to check.

I do know that to switch from a excited field to a permanent magnet alternator you will have to change the left side engine cover to match.

Suppose the above poster would be astounded to learn that I have a 83 GPz750 motor with a 79 KZ650 stator and rotor on it?


Either Rick's or Electrosport sell stators that they claim put out 10% more power.

Note that if you swap the stator you will need a corresponding reg/rec.

The 77 B1/C1 use a 3-phase excited field alternator with a separate regulator and rectifier that won't work with a permanent magnet alternator.

78 - 80 650 B,C,D(SR), E(Ltd) and F1 models use a 1-phase permanent magnet alternator (2 yellow wires coming out of the stator), you wil need a 1-phase reg/rec for these.

Not sure about the F2-F4 models (or the 750s for that matter) but the 650 H (CSR) models use a 3-phase permanent magnet alternator (3 yellow wires), you will need a 3-phase reg/rec for these.

The Hi-output Electrex stators are also 3-phase and need a 3-phase reg/rec.

Btw, Dave Sloan made a post about the Electrex stator a few months back, here's a link: CLICK

OK great. Thats exactly the info I needed. My 550 harness has the three yellow wires, and so does the old excited feild-that I will replace with a HO stator.

Now comes the hard part finding a side cover for the HO stator that I will be purchacing.

So if the info above is corect it would be safe to say that any KZ650, KZ750, GPZ 750 side cover will work as long as it has the permanent type magnet alternator. Right?

Snakebyte wrote:

So if the info above is corect it would be safe to say that any KZ650, KZ750, GPZ 750 side cover will work as long as it has the permanent type magnet alternator. Right?

I can't say for sure about the KZ 750 and GPz covers, I have no hands on experience with those models, but any 650 cover for permanent magnet will work. There is one issue, the cover dowel pins are located differently on the excited field covers and the permanent magnet covers - this is not a big deal though, you can just drill the cover (rather than the cases) to relocate the dowel pins. I have both types of covers, let me know if you want some pics.

Thank you.

No problem, you're welcome.

However, I just found out that the info I posted about the dowl pins is wrong - went out to snap some pics and realized that my memory played a trick on me, the cover I had to drill to make it fit my 77 B1 engine is not a stock cover but an aftermarket ribbed one.

The pic below shows a 77 B cover with stator and field coil (top) and a 79 D (SR) cover (bottom) with the Electrex stator I just installed when I put a fresh D engine in my 77.

As you can see the dowel pins are located the same on both covers, so you should be good to go with any 650 permanent magnet cover, sorry for the confusion. :blush:

I put a 78 KZ650B2 charging system on one of my 77s and yes the dowels were reversed so drilling was required.

:blink: The plot thickens, I'm beginning to think that there might not be a definitive answer to this question.

The pic below shows the original engine on my 77 B1 (pic is 5 minutes old), as you can see the dowel pins are positioned at 1 and 7 o'clock, my 79 D2 engine has the dowel pins sitting in the same positions as you can see comparing the covers in my previous posts.

What is really strange is the cover in the top pic above. This is the aftermarket cover I mentioned earlier intended for a 77 model as it has the mounting holes for the field coil that later covers don't have.

The strange thing about it is that I drilled the dowel pin holes in the red circles out myself, the original dowel pin holes are opposed (hidden by the gasket).

Anyway Snakebyte, long story short, you can make any 650 (and possibly 750 too) permanent magnet alternator cover work, if the dowel pin holes on the cover are positioned wrong you just drill the appropriate cover holes app. 1/8" deep with a 10mm drill bit to accept the pins.

Time for a beer...

Interesting, I looked at a 78 engine and the dowels are at 1 and 7 just like your pictures, however I looked at a 77 stator cover and the dowels in the engine would have to be at 5 and 7 to mount this cover.