by Roadie Dan
Note: Please read the instructions before attempting this procedure:
The stator installation is straight forward, but there are a couple of things that will make life easier as
you remove the OEM stator, and install the new.
First, leave the bike on the side stand, you do not have to drain
Lay some newspaper down under the bike, and have a small drip
pan ready to catch the small amount
This project will be done easiest if you remove the following items in this order:
1 - Right floorboard assembly.......the two bolts that attach
it to the frame.
2 - Front exhaust header, or whole system if you are running a 2 into 1
3 - Now you can remove the generator cover, but at the same time
The stator is bolted to the inside of the cover, the screws are Loctited & torqued at the factory..
you may experience difficulty in removing them.....
plan on replacing them because you probably will destroy the heads in the process of
At this point, stop & take a good look at where & how
everything is located.
Make sure when you put this all back together, the wires run the same way.
Also don't worry which wire goes where............the way the
Speaking of wires, here's probably the best tip I can give you
on this procedure.
The other thing that comes to mind is the generator cover gasket............
it's up to you how you want to do this, but you do have to
break the gasket where the two rubber grommets are, to be able to run the
new lead wires through. I carefully cut the gasket & lifted it up the area
around those grommets with a razor blade, and when I installed the cover
back on the motor, used RTV(silicone) gasket sealer & put the small piece of
gasket I took off back in place. I've put on 8000 miles, and it hasn't leaked yet.
Also you may find that the new wires are slightly smaller than
the OEM lead
As I said earlier, just be sure the new wires follow the same
pattern as the
That's about it.............the only other thing you may find is the way the
wires are attached to the new stator are oriented in the wrong direction.
The original stators were not made specifically for the Road Star, so the
way the wires came off the stator were actually backwards, so you had to
them go in the right direction. This was suppose to have been changed, but
closely compare the direction the wires come off the new stator to the OEM
stator. If this is true, then don't worry, just break off the tab, put a
small piece of that sleeving on as far as it will go to the windings on the
stator, and then the metal retainer in the cover will hold everything in place.
Once everything is attached in the cover it can't go anywhere.
From there, just reverse what you took off, remember to use Loctite
If you have any questions or problems, don't hesitate to contact
Take care, and good luck with your installation...........when
it's all done
Dan "ROADIE DAN" Rand............................................