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Remove stator from generator - Coleman Powermate Powermate 5000W Generator

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  • olde77
    olde77 Feb 18, 2012

    taking apart a Coleman 5kw genny.
    Stator starts to come forward past the rotor off the unit but seems to be prevented after about 1 inch of movement towards end of shaft. My assumption is that stator must be removed first before I can begin to remove rotor. Am I correct? Am I dealing with magnetism here?



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Northstar 5500. Voltage good. sounds and runs good. But, makes bad noise from gen head area when under any load. I replaced the bearing. Anything else?

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How to remove and replace the stator from a champion generator

You don't state what model you have. I just replaced the rotor on a Champion Model 41302 but removing the stator is the same process.

You will need to remove the muffler and muffler outer protection. Remove the bolts that hold the muffler outer protection. Remove the two bolts that hold muffler to the engine exhaust.

Take a block of wood and place it under the engine to support the generator. The supports on the generator head end will be removed so the generator will tip down and make it difficult to remove the stator.

Remove the generator end cover by removing two bolts.

Remove the two bolts that hold the muffler to the end cover.0834b898-460f-41f6-b0a0-6704ae605277.jpg

Remove the bolt that holds the ground from the generator to the frame.


Remove the two bolts that hold the end cover supports to the rubber supports to the frame.



Disconnect the quick connect electrical connectors and remove the 120/240 volt wiring from the terminal block. See second picture below.



Remove the ground from generator to wiring cable assembly by removing the bolt that connects it to the end cover. Yellow and green wire in picture above.

Remove the bolt from DC brush assembly and pull out of generator. Picture below shows assembly removed.


The stator and cover now can be removed from the generator. Take a rubber mallet to tap on the back of the brackets on the end cover to loosen it. The rotor bearing is seated in the end cover making it hard to remove by pulling by hand. Once lose pull straight out.

The stator can now be removed from the generator end by taking the four bolts out.

The installation process is the reverse.

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1 Answer

How to seperate the engine from the generator

Generators are getting more complicated due to the addition of solid state regulators and capacitors. In the old days, there was only brush pack and diode pack. If you would like to seperate the generator to repair the engine you must make sure not to damage wiring or brushes. You will need to remove the stator first so remove back cover to expose bolts holding stater to bell. Make note of all connections from stator to panel and remove all the wires. Remove brush pack if brush type. Pull stator out exposing the armature. Armature has center bolt to crankshaft (remove bolt). The armature is sitting on tapered engine shaft that may be rusty. Apply oil to shaft of engine directing oil to the tapered part (wd40 or similar) from the bell side and thru the bolt hole. Notice the two sides of the armature that are lamanated steel. Using small piece of hardwood against lamanated part rap solidly with heavy hammer once on each side being carefull not to damage metal or winding. Should pop loose with first or second hit. If no joy, re-apply oil but follow with a shot of carb cleaner. The carb cleaner will make the oil penetrate deeper /faster. Good luck

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1 Answer

Where is the stator on the model 580 3256 generator

On a motor or generator, the stator is the non-moving frame or housing. The stator holds the stationary electrical windings.


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1 Answer

How to remove generator from engine (model DGUH5S-2). 11 horsepower Honda engine.GX340 .

I have not worked on Dunlite generators, however have worked on many different brands using the GX340. When removing generator parts, one must keep in mind the brushes contacting the armature. Remove brush pack if any and set to side. Next unplug stator wiring making sure to draw diagram of connections. Remove bolts mounting generator/stator housing to frame and carefuflly pull off leaving only armature /rotor on the crank of the engine. Remove the long bolt thru rotor into crank. Now you will need to apply penetrating oil to the shaft of the engine to loosen the rust on the taper. It may take several applications. Place a piece of hardwood against
metal to protect the rotor and firmly rap with hammer on
both sides. You may need to use pry bar against engine
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1 Answer

How do I remove the generator from the engine on a LR 4400 Homelite?

Here is a copy of the owners manual and it has an exploded diagram that you can follow to remove the generator part. When you take off the back mount and then you will see inside a coil that rotates, this is the rotor, and a coil that is stationary around the rotor, this is the stator. Make sure that you take good photos and mark all wires that you disconnect, this helps in re-assembly later. To remove the back support called the brush head, you need to remove 4 long bolts and one in the center that holds the rotor to the engine. Gently tap the brush head away from the stator with a small hammer. You might need a small blade screwdriver to pry, remember GENTLE is the word here. Now, you might have to block up the stator so that it is supported since the brush head is removed. The stator might need some gentle prying to remove it from the engine. When pulling the stator off, be careful that you do not drag it on the rotor, this might damage the rotor. With the long bolt that held the rotor to the engine, screw it in and leave about 1/8" of it out so that the head does not make contact with the rotor shaft. Now with a small hammer, strike the head of the bolt while at the same time pulling on the rotor towards the head of the bolt. The rotor should come loose and you remove the bolt and pull the rotor off gently. To install, you never need to use the hammer to mount the parts.

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1 Answer

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