Broken crankcase cover, insides ok?

[wfooshee]

I think Skootie's point was all these 'Murrican suggestions for parts sources may not do him any good. Maybe they can ship, maybe not. How long does he have to wait to clear customs? What does he have to pay for that over and above purchasing and shipping? And some 'o them Yur-a-peeins have a VAT they're responsible for. Our guys don't handle that.

 

[iceaway]

So I managed to pull off the cover, but I didn't manage to undo the screws holding the stator in place. I know that using heat could make the loctite become fluid again, making them easier to remove. Would it be possible to use some kind of burner on the screws? My other idea is getting a T30 socket to use with my ratchet handle, do you think that is a way out?

If I need to remove the stator cover altogether to have a workshop remove the screws, I have to disconnect the cable. Do I need to remove the tank/seat to gain access to the connector, or can it be done from "the outside"?

 

[SwollenRaccoon]

Replaced mine about a month ago. Paid about $91 or so for the stator cover (from Ron Ayers), and I don't recall how much for the gasket. Didn't use an impact driver, and didn't replace the screws. After a few hundred miles, everything seems OK.

Repeating what's been said, the magnetic power is strong. I thought I still had something connected in there, like a cable stretching tight, or a spring of some kind. Then I remembered it was a stator cover I was removing (duh), not just a crankcase cover. I'm not very bright.

But you really should try to do the job yourself. It's not very difficult.

 

[iceaway]

Replaced mine about a month ago. Paid about $91 or so for the stator cover (from Ron Ayers), and I don't recall how much for the gasket. Didn't use an impact driver, and didn't replace the screws. After a few hundred miles, everything seems OK.

Repeating what's been said, the magnetic power is strong. I thought I still had something connected in there, like a cable stretching tight, or a spring of some kind. Then I remembered it was a stator cover I was removing (duh), not just a crankcase cover. I'm not very bright.

But you really should try to do the job yourself. It's not very difficult.

I managed to get everything out except for the screws that hold the stator to the stator cover. How did you get them out? T30 sockets seem to be quite hard to come by, and it seems I might have to order one online unless the burner-trick will do it. The bike is sitting down in the yard at the moment, and I don't think the landlord is too happy about it, so I really want to get this fixed asap

 

[Donal]

If it's just a matter of getting the stator+cover to a workshop, I would cut the three stator wires and get on with it. When you get the repaired assembly just re-connect the wires using in-line splices. You should be able to get these from any good auto shop.

One thing to bear in mind.... when you cut the wires make the cuts at different lengths about 20mm apart to help make a neater job when you re-connect. Otherwise you end up with a big bundle.

This is how NASA do it

Don

 

[iceaway]

If it's just a matter of getting the stator+cover to a workshop, I would cut the three stator wires and get on with it. When you get the repaired assembly just re-connect the wires using in-line splices. You should be able to get these from any good auto shop.

One thing to bear in mind.... when you cut the wires make the cuts at different lengths about 20mm apart to help make a neater job when you re-connect. Otherwise you end up with a big bundle.

This is how NASA do it

Don

I will keep this idea in mind! It's just that every time I have tried to undertake some kind of repair work on my bike, I've ended up at the workshop and paying twice for job (I appear to be a cursed DIY mechanic). For the sake of not feeling completely useless, I would really like to do it myself I've found one of those kitchen butane gas burners, which gives of a very nice small concentrated flame which I should be able to aim directly at the screws. I will give that a try, and if that doesn't work, workshop it is.

 

[SkooterG]

I think Skootie's point was all these 'Murrican suggestions for parts sources may not do him any good. Maybe they can ship, maybe not. How long does he have to wait to clear customs? What does he have to pay for that over and above purchasing and shipping? And some 'o them Yur-a-peeins have a VAT they're responsible for. Our guys don't handle that.

Thanks Walt! Somebody gets it.

 

[iceaway]

Heating it up didn't do anything, unfortunately. I'm going to try using an impact driver instead, hopefully that will get the screws loose.

 

[TomInPA]

A manual impact driver is inexpensive and very effective at removing those bolts. If you were in the USA I could recommend a number of places to pick one up, but I'm sure you don't have Ace Hardware or Harbor Freight where you live.

Anyway, the impact driver should keep the heads from stripping. .

 

[iceaway]

A manual impact driver is inexpensive and very effective at removing those bolts. If you were in the USA I could recommend a number of places to pick one up, but I'm sure you don't have Ace Hardware or Harbor Freight where you live.

Anyway, they will come out, and the impact driver should keep the heads from stripping. Worked for me.

I didn't even know such things as manual impact drivers existed, I wish I had known that earlier and got one from the start Unfortunately good hardware/tool stores appear to be much harder to find here in Sweden. And it can be quite challenging to convert your american brands/technical terms/tool names to their Swedish equivalents.

 

[TomInPA]

Manual or hand impact drivers are under $20 in the U.S. and to me are an essential piece of the tool kit for stuck bolts and screws. I got good use out of it when I attacked the PAIR cover plates on top of the valve covers, and of course removing the stator from my friend's 06 FJR (lowside crash). I'm sure they are somewhat common in Sweden at any good tool supplier, but then again, I don't know how to say Sears" in "Swedish.

 

[Donal]

A manual impact driver is inexpensive and very effective at removing those bolts. If you were in the USA I could recommend a number of places to pick one up, but I'm sure you don't have Ace Hardware or Harbor Freight where you live.

Anyway, they will come out, and the impact driver should keep the heads from stripping. Worked for me.

I didn't even know such things as manual impact drivers existed, I wish I had known that earlier and got one from the start Unfortunately good hardware/tool stores appear to be much harder to find here in Sweden. And it can be quite challenging to convert your american brands/technical terms/tool names to their Swedish equivalents.

Have a look here for a description and more importantly a picture of a manual impact driver.

Good luck with it

 

[iceaway]

A manual impact driver is inexpensive and very effective at removing those bolts. If you were in the USA I could recommend a number of places to pick one up, but I'm sure you don't have Ace Hardware or Harbor Freight where you live.

Anyway, they will come out, and the impact driver should keep the heads from stripping. Worked for me.

I didn't even know such things as manual impact drivers existed, I wish I had known that earlier and got one from the start Unfortunately good hardware/tool stores appear to be much harder to find here in Sweden. And it can be quite challenging to convert your american brands/technical terms/tool names to their Swedish equivalents.

Have a look here for a description and more importantly a picture of a manual impact driver.

Good luck with it

Thanks! Had a discussion earlier today with a more mechanically inclined friend who told me what it was and how to use it

 

[iceaway]

The impact driver worked like a charm. Got the stator away from the cover and it's now replaced. Waiting for the seal to set, and tomorrow I hope there won't be any leaks

 

[Niehart]

Well done iceaway. :clapping:

Now you know your more capable than you thought and my guess is that you will be doing more mechanical jobs on your FJR.

Still remember the first time I took off the fairing plastic, I was sure that I would screw something up.

 

[Mount Rainier]

Well done iceaway. :clapping:

Still remember the first time I took off the fairing plastic, I was sure that I would screw something up.

Me Too! And I did......

Keep Going!

 

[Donal]

Excellent work and well done for sticking with it :clapping: especially having to work in the conditions that you have.

Don

 

[iceaway]

Thanks for all the encouraging words :drinks: After my last failure with the fork rebuild I really needed fix something from start to finish.

Only thing bugging me now is that I managed to break one of those stupid plastic "screws" that sits on the inside of the side fairing :fool:

 

[wheatonFJR]

Only thing bugging me now is that I managed to break one of those stupid plastic "screws" that sits on the inside of the side fairing :fool:

You weren't the first, believe me.

 

[Canadian FJR]

Can the stator cover be replaced without draining the oil?

Canadian FJR