Friday, 6 September 2013

ER6n -09 Stator Coil, Brake Pads replacement

Recently having my bike having a weak battery after rides, after check the charging system with a multimeter according to manual procedure, it is obvious that the stator coil is defective. The charging system on automotive consist of two section, the stator coil which is part of the generator assembly which generate electricity and the rectifier which convert the high AC voltage out put from generator to DC voltage.

Basically how we know when out charging system is defective is by first detect the charging voltage with bike running and extra accessories off.

Normal bikes will have a charging voltage of around 14 DCV when slightly rev up and around the battery voltage (most battery have a voltage of 12.7 V when fully charged) when idealing.

If you are not getting the figure, unplug the stator socket, run the bike on battery power and test the AC voltage, a normal stator will have a AC voltage of 30-50 DCV when rev up to mid range which is around 4k or 5k RPM according to bike manual. If the DCV is a lot lower it means that your stator is showing a problem. There is also a possibility of rectifier problem when running the bike on charging voltage but most of the time when a rectifier fail, the unit will instead burnt off and you will know immediately, your machine will dead when the battery drain. Most people are having Stator Coil replacement because unlike car alternator unit which is outside the engine, bikes' alternator have to integrate to the engine and result in a less effective cooling.

Locate your alternator location and remove the stator socket

Unscrew the stator coil cover and remove the cover from the engine housing
Unscrew the 3 bolts on the stator cover and remove the old stator, do remove the wire lead cover also.

Replace the stator coil with a new unit, in my case I use a after market stator from Ricks Motorsport Electronics USA.

After fasten the stator coil, do not forget to apply engine gasket sealent at the stator coil wire lead area.

 Before putting on new gasket at the engine cover, make sure the two points where up and down engine housing meets are applied with engine gasket dressing. Walla your stator change is done. Connect the stator socket and check is the charging system well functioned.

Brake Pads Replacement

It is very easy to do your own brake pads replacement, in fact it is the easiest self maintenance to do.

First, replace unscrew the 12mm bolts which hold the brake calipers

Then use a screw driver to applied pressure to the pads so that the extra spaces make your insert easier.

Remember to remove the pin at the back of the calipers so that you can remove the rod which lock them up.

Replace the brake pads back and insert it in a reverse sequence, walla, you got your new sets of brake pads.

New brake pads, you can see the significant thinkness

Old brake pads, almost worn out


  1. I'm riding a 06 ER6N and recently changed to a aftermarket stator from Ricks.Few months later it gave me problem.Does yours gave any problem?

    1. Hi Booger, actually the connector socket did burnt off a little and melt a small portion of it, it makes them stick together and unable to removed but recently i am finally able to seperate them. But then, i have to carefully connect it together else there will be a problem to receive proper charge for the battery from the stator. How about your problem?

  2. I bought stator coil and rectifier from Ricks back in May,fixed it and it was ok for 2 months.then 1 day while riding a sound like the starter being continuously engaged came.Brought it to a mech,he said the relay assembly is faulty.So changed to new one.Few days later the starter sound came again and headlight died.I sent my bike to kawa dealer in JB.He found out that the aftermarket coil is causing the relay to be faulty.So I change to brand new original coil and 2nd hand relay and all is well or so I thought.Just 2 days ago while riding at night,the headlight died and the whirring starter sound came on again! FML!

    Just ytd (mon) I went back to JB to have it check again.He asked me whether I did any modification to the starter motor.I said no,only used the aftermarket rectifier.He swapped to an original 2nd hand rectifier.He did more test using voltmeter to see if there is any overcharging and cleaning of the wire connections.He thinks the aftermarket parts are causing all this problems.The problem is fixed now.I hope no more weird starter sound came again!

  3. Hello jinhau....just want to ask something....if i want to open the stator coil cover, is it must drain out the engine oil first?