Stator and Kokusan Flywheel Kit for Aprilia RSV4, Tuono 1000 V4 & Tuono 1100 V4 2011-2020
Stator and Kokusan Flywheel Kit for Aprilia RSV4, Tuono 1000 V4 & Tuono 1100 V4 2011-2020
SKU:RMS900-103848
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Improved Stator and Kokusan Flywheel Upgrade Kit
Aprilia RSV4 2011-2020, Tuono 1000 V4 2011-2015 and Tuono 1100 V4 2016-2020 - Part RMS900-103848
This is a complete heavy-duty recall-type charging system upgrade kit for the Aprilia RSV4 and Tuono V4. Anyone who rides or repairs these motorcycles is likely to be familiar with the stator, flywheel and sometimes voltage regulator problems common to the range. Most of these bikes will have had at least one stator failure in their lifetime so far, and fitting a replacement stator on its own rarely solves the problem for long.
The root cause was the extremely strong magnets used on the original flywheels. These created a very high power stator output, which in turn generated excessive heat. The usual result was burned up or shorted stator windings, and often a failed voltage regulator alongside. The solution developed for these engines was a new flywheel from Kokusan using lower strength magnets, dropping the stator output and the heat generation with it. That gives a charging system output properly matched to the bike's electrical needs, and long term reliability from both the stator and the voltage regulator. This kit supplies the heavy-duty Kokusan brand recall-type OEM flywheel, a triple-tested heavy-duty stator, and the flywheel puller needed to fit them.
Key Features
- Heavy-duty Kokusan brand recall-type OEM flywheel included
- Triple-tested heavy-duty replacement stator included
- Matching flywheel puller included, 36 mm x 1.5 right hand male thread
- Lower strength flywheel magnets reduce stator output and heat generation
- Helps protect the voltage regulator rectifier from heat-related failure
- Complete charging system solution rather than a single component
- Three stator wires into a single 3-pin plug, matching the original layout
Technical Specs
| Specification | Detail |
|---|---|
| Stator interior diameter | 43 mm |
| Stator exterior diameter | 105 mm |
| Stator thickness | 13.8 mm |
| Wire length, stator to grommet | 125 mm |
| Wire length, grommet to plug | 320 mm |
| Number of wires | 3 |
| Number of plugs | 1 |
| Number of pins | 3 |
| Alternator resistance, yellow to yellow | 0.3 ohms +/- 20% |
| Flywheel exterior diameter | 121 mm |
| Flywheel interior diameter | 107 mm |
| Flywheel centre housing, interior diameter | 19 mm |
| Flywheel centre housing, exterior diameter | 33 mm |
| Flywheel thickness, exterior | 35.3 mm |
| Flywheel thickness, interior | 30.65 mm |
| Puller thread | 36 mm x 1.5 right hand male |
| Puller length | 60 mm |
| Puller exterior diameter | 48 mm |
| Puller interior diameter | 35 mm |
| Puller centre housing, exterior diameter | 37 mm |
Vehicle Fitment Guide
| Make & Model | Years |
|---|---|
| Aprilia RSV4 | 2011-2020 |
| Aprilia Tuono 1000 V4 | 2011-2015 |
| Aprilia Tuono 1100 V4 | 2016-2020 |
OEM Part Number Cross Reference
Aftermarket replacement. OEM part numbers are listed for reference only.
| Part Number | Manufacturer / Brand |
|---|---|
| 897479 | Aprilia - stator |
| 1A010574 | Aprilia - stator and flywheel |
| 2D000049 | Aprilia - stator and flywheel |
| 020913Y | Aprilia - flywheel puller |
Frequently Asked Questions
Will this kit fit without modification?
Yes. It is a direct replacement for the original charging system components on the models and years listed above. The stator carries three wires into a single 3-pin plug, matching the original layout, and the flywheel is the Kokusan recall-type OEM unit. No cutting or splicing is required.
What is included in the box?
Three items: the heavy-duty Kokusan brand recall-type OEM flywheel, the triple-tested heavy-duty stator, and the flywheel puller required to remove the original flywheel and fit the new one.
How do I know my stator has failed?
Typical symptoms are a battery that will not hold its charge, dimming lights, and a charging voltage that stays low as engine speed rises. On a healthy unit the wire to wire resistance between each yellow wire measures 0.3 ohms plus or minus 20 per cent. Visible discolouration or burning on the windings confirms the diagnosis.
Why replace the flywheel as well as the stator?
On these engines the original flywheel magnets are the root cause of the failures. Fitting a new stator to the original strong-magnet flywheel leaves the same excessive output and heat in place, which is why replacement stators often fail again. The Kokusan flywheel supplied here uses lower strength magnets, so the new stator runs within its designed temperature range.
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