Stator replacement questions

[Eric Peterson]

What I did might not have been the "incredibly experienced GS forum member solution", but it worked: I took as much off with razor blade as I could, then used a small sanding wheel (like the modeling kind Dremel makes) to carefully remove big pieces left, then by-hand fine sandpaper to smooth the edge. Right before reassembly with the new gasket I ran some fine steel wool around the edge and wiped every little bit of grit off I could.

Hope this helps!

[jbs80106]

UPDATE - Putting her back together

Thanks again for all the help. Last night I put the new gasket in place, threaded the wires thru the hole into the starter area and secured the side cover in place with a couple of the screws.

Latest question is how tight to tighten the bolt for the side cover? I'm securing them with the blue loctite but recall reading not to over tighten them as they're going into the aluminum block.

My manual didn't seem to list torque settings for the bolts, should the tight...but TIGHT!!!

I'm using a ratchet to put them in and have tightenend them to reasonable hand strength but haven't leaned onto the ratchet with my body weight if that makes sense....

Cheers!

[twr1776]

Do NOT overtighten the case cover bolts. They are probably only 6 mm bolts and you can snap them off. My manual does not specifically give a torque for the case bolts but notes for all bolts of that size on the bike to go to 3 - 5 lb-ft. I did not use a torque wrench on mine. I used a 1/4" drive and just tightened them. I also would not use the blue loctite. I just used assembly lube and did not overtighten them. You probably know this already but when you tighten the bolts do it in a star pattern. Just sung them the first time,
check all around the case for good gasket contact and then go around again. I will snug slightly more the second time and then go around the third time with the final tighten. Happy charging

[jbs80106]

funny you shouldl mention it...

You mentioned to be careful to not overtight as the bolts can snap off...

I changed modes this evening and was reinstalling the battery holder bracket, tightend up on the first bolt and it just sheared off....fortunately I could just un do the broken off bit. I didn't torque it much...maybe just don't know my own strength!

I'll do the star patter and the multipass tightening. I really can 'see' much of my gasket round the outside of the side cover. I assumed it was just a good fit....

[twr1776]

I also have a tendency to overtighten. The aluminum threads are easy to strip and it also seems that the heat or age can make these old bolts brittle. Most of the time I replace the original bolts if I can. If you are doing a few other things the assembly lube/anti sieze is great stuff to use. I use it on about everything I re-install and it should keep corrosion out of the threads. On these bikes most steel bolts are in aluminum and it seems that the different materials oxidize together making them difficult to remove. I don't have any scientific proof but it sure seems that way.