Feed stator wires through cover gasket?

[Guest]

What in the wide world of sports is going on here?

Do I have to pull the stator wires from the harness to feed them through the gasket on the stator cover?

Man oh man. I am very tempted to put a slice in the gasket and avoid this as
I already changed the R/R this year and dang if I want to pull all them wires apart again!

Any tips for this?

Thanks,
-Bob

[posplayr]

The obvious answer is the only one. I just cut my soldered stator wires and resoldered them for the same purpose. If you are in the habit of swapping stator covers, then use spades

[propflux01]

I am alittle confused on what your asking here, as your stator should have its own wires that feed through a grommet, to the upper right portion (as your facing it) of the cover, then through the starter cover, out the backside (left side of bike out of the starter cover) and then solder directly to the regulator wires. You should not have to route any of the bike's harness through the cover.

[bwringer]

Yes, the stator wires go through the gasket, if I'm understanding your question correctly.

Your plan of a slice in the gasket should work -- just patch it with a dot of case sealer (preferably not RTV silicone) and it should be fine. Not much oil gets splashed up there.

[Clone]

This is apparently different from my bike as the stator wires go through a rubber grommet you can pull the wires through, there is no need to slice any gaskets, at least on an 83.

[propflux01]

This is apparently different from my bike as the stator wires go through a rubber grommet you can pull the wires through, there is no need to slice any gaskets, at least on an 83.

Mine is the same way, hence my curiosity...

[almarconi]

On my stator, the wires had a grommet molded into the wires. You put the grommet in the cover then put the gasket on. No need to cut the gasket.

[jwhelan65]

On my stator, the wires had a grommet molded into the wires. You put the grommet in the cover then put the gasket on. No need to cut the gasket.

Mine is the same way, I actually have mine off right now. Is there any need for permatex or some form of sealent along with the gasket?

[almarconi]

You can use sealant if you want. Hylomar or Ultra copper works well. I like to adhere the gasket to the cover so it doesn't move around while installing it.

[propflux01]

I have never used any sealant on mine, I just oil the gasket, and install it.

[bwringer]

I was under the impression that the OP wanted to replace the gasket yet avoid disconnecting the stator wires from the bike -- it had nothing to do with the grommet.

To do this, at least with all the GS stator covers I've seen, you would need to cut a slit in the gasket.

The wires go through the grommet and enter a little "chamber" at the top of the stator cover, where they're then threaded through a hole into the starter cavity. You would need to cut the gasket at this "chamber" to install a new gasket without removing the wiring from the bike.

And come to think of it, this chamber doesn't have any oil in it, so you wouldn't need to re-seal the gasket.

The chamber I'm talking about is at the bottom of this photo of a stator and cover from a 1979 GS850.

[littleroot]

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[Raven457]

The wires go through the grommet and enter a little "chamber" at the top of the stator cover, where they're then threaded through a hole into the starter cavity. You would need to cut the gasket at this "chamber" to install a new gasket without removing the wiring from the bike.

And come to think of it, this chamber doesn't have any oil in it, so you wouldn't need to re-seal the gasket.

He may need to seal the grommet though if he ever installs a new stator. I had to hollow out a channel in the grommet to feed my new Electrosport stator wires through. You can see some of the cut here in this pic - http://ravensys.net/sa/bike_newstator.jpg

After trimming enough material away so that the top of the grommet sat flush with the rest of the gasket surface, I shot a bit of red RTV into the channel I carved into the grommet to keep things sealed.

[littleroot]

I was under the impression that the OP wanted to replace the gasket yet avoid disconnecting the stator wires from the bike -- it had nothing to do with the grommet.

To do this, at least with all the GS stator covers I've seen, you would need to cut a slit in the gasket.

The wires go through the grommet and enter a little "chamber" at the top of the stator cover, where they're then threaded through a hole into the starter cavity. You would need to cut the gasket at this "chamber" to install a new gasket without removing the wiring from the bike.

And come to think of it, this chamber doesn't have any oil in it, so you wouldn't need to re-seal the gasket.

The chamber I'm talking about is at the bottom of this photo of a stator and cover from a 1979 GS850.

Right. You explained it well and I'll prove it (or be red faced) by showing the gasket and my cover.

I'm with you: My choices are I have to cut the gasket or disconnect the stator wires and run them through the small cavity. The grommet should keep oil out of the little cavity. To my unexperienced eyes I'd say it's probably what the grommet and cavity are for: to allow us to cut the gasket and slip the wires in there.

Gasket


Stator cover

[jwhelan65]

Could you could remove the starter and slide them through individually ?