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How to Troubleshoot the Stator on a Suzuki Z400

    Wiring

    • 1). Remove the bolts that secure the seat and fender fairing in place with a metric socket and ratchet. Lift the fairing enough to disconnect the taillight wire from the back of the light. Remove the fairing to access the stator wiring.

    • 2). Trace the path of the stator wire that exits the timing housing at the upper right side of the engine. Identify a black wire connector at the main wire harness. Disconnect the connector from the main wire harness by depressing the tab by hand.

    • 3). Set the voltage meter on "Ohms." Insert the pin from the red meter wire into the female port at the bottom of the connector.

    • 4). Insert the pin from the black meter wire into each of the upper ports on the connector, one at a time as you note the reading on the meter each time. Typical continuity at each port is 1.2 to 2.5 ohms. Replace the stator if the meter doesn't show a reading. If the reading is lower than 1.0 ohms, troubleshoot the stator.

    Stator

    • 1). Loosen and remove the Allen bolts that secure the timing cover to the timing housing on the upper right side of the engine with a metric Allen wrench. Pull off the timing cover by hand to access the timing plate and the stator.

    • 2). Loosen and remove the timing plate bolts with a metric socket and ratchet. Pull off the timing plate by hand to access the stator.

    • 3). Pull the stator out of the timing housing and inspect the magnetic contacts at the outer ends of each copper winding. Replace the stator if you notice pits or burned spots on any contact. If the stator is in good condition and the ohms test was satisfactory, the problem is elsewhere.

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