Replacing left side magneto- stator? cover

I just recieved a new mag - stator (I have seen it referred to as both) cover. Is replacing it as straightforward as it appears or is there a gremlin waiting. Appears to just need to remove the hex bolts and replace gasket. Does oil need to be drained first?

Thanks

Its more or less straight forward. First, there is a world class amount of magnetism trying to keep you from pulling it off. There is also a gear that will be falling off. Then the screws that hold the stator to the inside of the cover are a ***** kitty to loosen. And when you go to put the cover back on, watch your fingers. Everything will be going very smoothly, then in a tenth of a nano second, the magnetism is going to suck the whole thing on so fast and hard that you will just be a spectator. Make sure your fingers are not in harms way. Watch the wires are routed properly.

If you have a decent amount of mechanical aptitude, it's not really too bad. Be sure to buy a new gasket first. And no, you don't need to drain the oil first, but you will get a little bit that will drain out of it - but not much.

One more thing, there are three (I think) thingies that hold wires in place on the outside of the cover. You can see them just by going out and looking at the bike. One trick I have learned is to use your digital camera to take all kinds of picture angles of things before you take them apart. Otherwise there is a good chance you'll forget which way all of those things mount.

Also, the bolts that hold the cover on are not all the same length. Make a note as to where the oddball (I think shorter, if I remember right) bolts go. It won't be as obvious as you might think. Don't ask me how I know.

To add to jjsC6's comments, DO NOT OVERTORQUE. I did and stripped one bolt - be careful!

Good advice was given in this oddly similar thread here and here.

One other thing I would add, be very careful with the little bracket that holds the stator wires to the stator magneto cover, if it bends even in the slightest it will score a grove in the rotor. This is covered in the ElectroSport How-To’s. You will also find more about the stator cover in the ElectroSport threads like this one.

QUOTE (Flyguy @ May 18 2008, 02:45 AM) <{POST_SNAPBACK}>
I just recieved a new mag - stator (I have seen it referred to as both) cover. Is replacing it as straightforward as it appears or is there a gremlin waiting. Appears to just need to remove the hex bolts and replace gasket. Does oil need to be drained first?

Thanks



Some pictures I took during my change (click on each for a bigger version):
1st three show external wiring:
(Click on image for larger view)


Undo the 11(?) bolts, but slacken them in a criss-cross order to prevent the cover warping (and when re-assembling, tighten them gradually in a criss-cross manner). I laid mine out in order, starting from the bottom one and in a counter-clockwise removal order. (Only one is different from the rest, but I didn't know that when I removed them.)

Pulling the cover isn't easy. That's a really strong magnet on the rotor. When it does come you'll tend to pull it too far, try not to, the wires don't stretch .

Next shows the stator removed:


Note the gear wheel. I've put it on the cover, but when you pull the cover, the gearwheel stays with the crankcase. Its axle is a peg free to move onto the cover or the main part. The gearwheel is assembled behind the rotor (I think it's shown the wrong way round in my pic, but it will be obvious. I only put it there to keep it somewhere clean while I took the pic). For re-assembly, you put its axle and it on the crankcase.

The wire is clamped in the cover, no problem there; the grommet that the wire goes through just slides out of the case.

And another view showing how I kept the weight off the wires!


You only need to drain a little oil, about a litre (two pints), undo the oil drain bolt, hold it so as to allow oil to drain slowly. Watch the level in the sight glass, when it's below the bottom of the cover, voila! screw it back in. (Then wash the oil off your hands.)

Undoing the stator screws took some effort, I had to use a tube spanner as a lever extension on my torx key. I didn't disconnect the wires, I used a chair as a workbench beside the bike to work on the cover.

I didn't do a full write-up, but it's not very hard; hope this helps a bit.

Use a hand impact driver on the 3 Torx (anti-tamper) screws inside the cover. They are red lock-tighted in place. Be sure to relock-tight.

Am I glad I posted on this one! This forum is indespensible if you have an FJR.

Thank you all very much.

Flyguy said:

Am I glad I posted on this one! This forum is indespensible if you have an FJR.
Thank you all very much.

Click to expand...

Yep,

Darn guys on this forum seem to know how to do everything. My question? Now that you know whats involved are you gonna take it to the dealer or do it yourself? Looks easy tho.