Stator Replacement - Parts list

Decided I don't want to tackle the stator myself.  Other than the actual stator, what's on the parts list to get so the mechanic has the best of everything he needs? (BTW, I did search and couldn't cobble together a comprehensive list or determine whether a flywheel was needed on a 2000)

A new stator cover gasket.  You'll lose a teaspoon of oil but that shouldn't matter.

if you can put your pants on and ties your shoes. you can change a stator. :happy:

[image: View Post]gll429, on 26 March 2012 - 09:03 PM, said:

if you can put your pants on and ties your shoes. you can change a stator. :happy:

There are many things I can do I have no desire to do.  I believe in becoming one with my bike, but I'll take it slow and get to know her over time.  At this point, I have spent over 40 hours on mods in the last 45 days and I'm happy to let someone else do this.

changing the stator requires an allen key and a new stator..  and a gasket or gasket maker permatext.

remove lower plastic..
unplug stator..
remove the engines left side  round cover.
remove stator from cover ( 4 bolts)
install new stator.. apply permatex.. to old gasket or get new gasket..
install cover. plug in stator
. install lower .. go riding..
you can do it in 20 min :fing02:

[image: View Post]gll429, on 26 March 2012 - 11:38 PM, said:

changing the stator requires an allen key and a new stator..  and a gasket or gasket maker permatext.

remove lower plastic..
unplug stator..
remove the engines left side  round cover.
remove stator from cover ( 4 bolts)
install new stator.. apply permatex.. to old gasket or get new gasket..
install cover. plug in stator
. install lower .. go riding..
you can do it in 20 min :fing02:

I like 20 minutes.  I don't want to screw it up.  I essentially just want to ride.  

But, I'm cheap enough to consider.  So far I read two things that folks have complained about.

• Installing metal clip from original on wiring of Rick's R/R to replace a nylon tie (some have left the nylon, but not sure on this)
  
• Routing the wiring to the other side of the bike without removing airbox, which I assume means taking off the gas tank

Have you done this?  With a R/R from Ricks?

Also, is there any screwing with the flywheel necessary?  I saw some say they replaced it, but I think that was a 6th gen.  I have a 2000.

You don't have to mess with the flywheel.  However, due to the magnets in the stator it will feel as if the stator cover is stuck, it's not really.  Just keep that in mind.

Trace the wires from the stator to the plug to harness... found it???
Can you get to it with out taking apart the bike? If yes.. replace that stator!

[image: View Post]realistdreamer, on 27 March 2012 - 01:28 PM, said:

[image: View Post]gll429, on 26 March 2012 - 11:38 PM, said:

changing the stator requires an allen key and a new stator..  and a gasket or gasket maker permatext.

remove lower plastic..
unplug stator..
remove the engines left side  round cover.
remove stator from cover ( 4 bolts)
install new stator.. apply permatex.. to old gasket or get new gasket..
install cover. plug in stator
. install lower .. go riding..
you can do it in 20 min :fing02:

I like 20 minutes.  I don't want to screw it up.  I essentially just want to ride.  

But, I'm cheap enough to consider.  So far I read two things that folks have complained about.

• Installing metal clip from original on wiring of Rick's R/R to replace a nylon tie (some have left the nylon, but not sure on this)
  
• Routing the wiring to the other side of the bike without removing airbox, which I assume means taking off the gas tank

Have you done this?  With a R/R from Ricks?

Also, is there any screwing with the flywheel necessary?  I saw some say they replaced it, but I think that was a 6th gen.  I have a 2000.

If you're still considering DIY, 2 things that helped me were that 1.  I got 2  6mm bolts about 3" long and cut the heads off, putting them in place of two of the OEM cover bolts 180 degrees from each other.  That forces the cover to go on straight as the magnets want to pull it off center.  The second was I had a helper hold the cover while I removed the 4 bolts that retain the stator to the inside of the cover.  It was difficult to hold the cover with one hand while breaking the bolts loose with the other.   I replaced the R/R on my '99 with a Rick's, and it just plugged right in.  I think the wiring crossover you're referencing is on a 6th gen where the R/R is on the opposite side of the frame as the stator.  On yours the R/R is on the same side, so it's very easy.

OK now I'm really confused.  On my bike (2000) the stator is on the right and the R/R is on the left.  Am I missing something???

The clutch is on the right side, the Stator is on the left side.  On the 2002+ bikes the R/R is on the right side creating the need to fish the wires across the motor rather blind.

It shouldn't be an issue with your bike...I like the suggestion of using 2 long 6mm bolts as alignment pins as well.

Thanks.  I guess I'll give it a try.  If I screw it up I'll be back here for suggestions.  Otherwise, I'll have pictures for the next newbie with questions.  This is more adventurous that I was on my last bike, but I'm game.

Will I need to cut the heads of the 6mm bolts?  Don't think I have a tool (other than a new blade for my hacksaw) for that.

The 6mm bolts to line it up, although being handy, completely un-necessary, if you're stronger than a 12 year old boy then you won't have any time setting it on the dowels and then putting your bolts in.

Got my stator and R/R from Ricks.  

The Shop Manual says I need some sealant for the wire grommet that looks to connect the wiring to the stator.  Any suggestions on the type of sealant?

Also, do I need to get a torque wrench?  The torque specs are 12 N-m or 9 ft/lbs.

For sealant, go to any auto store and get gasket maker high temp sealant.  I used silver one.  You'll need a tiny bit of it.

Torque wrench I wouldn't use.  Just use a 1/4 drive ratchet and hand-tighten it keeping in mind that that block is aluminum and not too much torque in needed - One hand on the wrench only.  If the torque wrench is wrong, you'll be screwed. (NPI :rolleyes: )