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Ok. I bought new stator and R/R from electrosport and installed sat and sun. It was a bigger job then expected. My comments below...
First. Do NOT bother trying to remove the old RR from the bottom of the battery box from the side of the bike as bikecliffs incredible site depicts. He is awesome but sadly incorrect in this case. I tried and tried. Finally I got smart and removed the battery box. Lol !!! It only took me 5 minutes. It's easy as can be. To remove the box, take the seat and side covers off. Remove battery. Then look down at the box. If you are standing at the left side of the bike, you will see two bolts facing up to the right of the box (towards rear of bike). Remove them. You will see two black electrical box units hanging on clips on the battery box directly across from you over on the right side of the bike. Lift them both straight up off the clips they are on. Leave them hanging. Now, you might think you could lift the box out but there is one screw going into the top bracket of the battery box that must be removed. Look down in the box as you stand on the left side of the bike. You can see it going in from your side directly into the top bar of the box. Remove it and lift the box off the rod on your left. It comes right out. Flip the box over on the ground and have it it with your impact screwdriver. A couple good whacks and those screws came out.
Now. You need to go to hardware store and get two new socket head screws. They are metric M6 1.0 threads. Get them 1.25 " long or approx metric equivalent. Get a couple lock washers too. You also need a couple 4mm bullet electrical connectors and one female 4mm. The reason you need this **** is that the RR comes with a big 4 place connector that ain't no good to you. So I pulled the connectors out of the plastic socket by pressing a tiny screwdriver into the socket to depress the metal edge of each spade and pulled the wire and spade out. 4x. Then I pulled the spade off. I did this because the wire harness looked quite short and I didn't want to loose any length by snipping it off. Thank god I did because you need all the length. Now look at your old rectifier and put the bullets on he correct wires and the female on the other. Now, you can plan on using the ground wire one of two ways... One, you can ground it to the RR mount bolt. But I didn't think that would provide a great ground. So I tried to reach the battery term with it. But it's too dang short. So I soldered 2 " lead on it. And took it to battery terminal.
Now. For the stator. You need an impact screwdriver. I got a cheapie from auto store. Was like 10 bucks. Carefully loosen all the screws and remove the stator from the side plate. Take it out. Btw I just cut the old stator wire off to take off side plate.
Now. You may find, as I did, that the stator has a dang bracket on it that is inconveniently located. It is in a bad place and didn't allow me to make the thick harness take the tight turn up the side wall. So I removed the bracket by taking two needle nose pliers and bending the bracket off the wire. I removed the screw holding the bracket and took it off. Now, I mounted the stator and wrapped the harness snug underneath the stator, around and up the sidewall. That worked good. That harness won't move and its held tight by the sidewall bracket. Make sure you get that bracket snug to the sidewall and pressing straight down. Now route the harness around and screw the screws in to hold it. You are ready to go.
You need a new gasket man. Mine was petrified and broke. It was really tough to get the side plate broken free. I beat the snot out of it with a rubber mallet. Then I got a hair dryer and heated up the side plate and beat the snot out of it again until it finally broke free. Put the new gasket on first. Use something tacky and mount the gasket on the bike prior to installing the stator and plate.
There. I just saved you a ton of time. Because I had some major time eating roadblocks. One, i tried forever to remove the RR from the side. That's dumb. Take off the batt box man !! Two, needed new bolts for RR. The electrosport RR is THICK at the mount location. It's about 3/4" thick. You need a 1.25" or approx m6 1.0 hex head bolt to remount. Three, that stator needs the harness bracket removed. It won't fit otherwise. Four, that RR needs new connectors. That four place connector don't help !
Anyhow. I got it hooked up and it charges perfectly. I still ran it all stock so I didn't bypass the headlight harness as many suggest on the site. I was just too beat to figure that out. I just installed same as I took it off. But it works perfect. 14.4v. I may go back later and bypass the headlight circuit.
Thanks all.
First. Do NOT bother trying to remove the old RR from the bottom of the battery box from the side of the bike as bikecliffs incredible site depicts. He is awesome but sadly incorrect in this case. I tried and tried. Finally I got smart and removed the battery box. Lol !!! It only took me 5 minutes. It's easy as can be. To remove the box, take the seat and side covers off. Remove battery. Then look down at the box. If you are standing at the left side of the bike, you will see two bolts facing up to the right of the box (towards rear of bike). Remove them. You will see two black electrical box units hanging on clips on the battery box directly across from you over on the right side of the bike. Lift them both straight up off the clips they are on. Leave them hanging. Now, you might think you could lift the box out but there is one screw going into the top bracket of the battery box that must be removed. Look down in the box as you stand on the left side of the bike. You can see it going in from your side directly into the top bar of the box. Remove it and lift the box off the rod on your left. It comes right out. Flip the box over on the ground and have it it with your impact screwdriver. A couple good whacks and those screws came out.
Now. You need to go to hardware store and get two new socket head screws. They are metric M6 1.0 threads. Get them 1.25 " long or approx metric equivalent. Get a couple lock washers too. You also need a couple 4mm bullet electrical connectors and one female 4mm. The reason you need this **** is that the RR comes with a big 4 place connector that ain't no good to you. So I pulled the connectors out of the plastic socket by pressing a tiny screwdriver into the socket to depress the metal edge of each spade and pulled the wire and spade out. 4x. Then I pulled the spade off. I did this because the wire harness looked quite short and I didn't want to loose any length by snipping it off. Thank god I did because you need all the length. Now look at your old rectifier and put the bullets on he correct wires and the female on the other. Now, you can plan on using the ground wire one of two ways... One, you can ground it to the RR mount bolt. But I didn't think that would provide a great ground. So I tried to reach the battery term with it. But it's too dang short. So I soldered 2 " lead on it. And took it to battery terminal.
Now. For the stator. You need an impact screwdriver. I got a cheapie from auto store. Was like 10 bucks. Carefully loosen all the screws and remove the stator from the side plate. Take it out. Btw I just cut the old stator wire off to take off side plate.
Now. You may find, as I did, that the stator has a dang bracket on it that is inconveniently located. It is in a bad place and didn't allow me to make the thick harness take the tight turn up the side wall. So I removed the bracket by taking two needle nose pliers and bending the bracket off the wire. I removed the screw holding the bracket and took it off. Now, I mounted the stator and wrapped the harness snug underneath the stator, around and up the sidewall. That worked good. That harness won't move and its held tight by the sidewall bracket. Make sure you get that bracket snug to the sidewall and pressing straight down. Now route the harness around and screw the screws in to hold it. You are ready to go.
You need a new gasket man. Mine was petrified and broke. It was really tough to get the side plate broken free. I beat the snot out of it with a rubber mallet. Then I got a hair dryer and heated up the side plate and beat the snot out of it again until it finally broke free. Put the new gasket on first. Use something tacky and mount the gasket on the bike prior to installing the stator and plate.
There. I just saved you a ton of time. Because I had some major time eating roadblocks. One, i tried forever to remove the RR from the side. That's dumb. Take off the batt box man !! Two, needed new bolts for RR. The electrosport RR is THICK at the mount location. It's about 3/4" thick. You need a 1.25" or approx m6 1.0 hex head bolt to remount. Three, that stator needs the harness bracket removed. It won't fit otherwise. Four, that RR needs new connectors. That four place connector don't help !
Anyhow. I got it hooked up and it charges perfectly. I still ran it all stock so I didn't bypass the headlight harness as many suggest on the site. I was just too beat to figure that out. I just installed same as I took it off. But it works perfect. 14.4v. I may go back later and bypass the headlight circuit.
Thanks all.
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