Tools and Materials:
- Basic hand tools (wrenches, sockets, screwdrivers)
- Gasket maker
- New stator
- Cover gasket (if necessary)
Procedure:
Step 1: Preparation
- Disconnect the negative battery terminal.
- Drain the engine oil.
- Remove the exhaust pipes and air cleaner assembly for better access.
Step 2: Remove Outer Primary Cover
- Locate the outer primary cover on the left side of the motorcycle.
- Remove the bolts securing the cover and lift it off.
Step 3: Remove Primary Chain
- Inside the primary cover, you'll find the primary chain.
- Loosen the adjuster bolts and remove the chain by pulling it up and out of the case.
Step 4: Remove Rotor Assembly
- On the backside of the primary chain, you'll find the rotor assembly, which houses the stator.
- Remove the bolts securing the rotor and carefully lift it off.
Step 5: Replace Stator
- The stator will be located underneath the rotor assembly.
- Disconnect the stator wires and remove the mounting bolts.
- Remove the old stator and replace it with the new stator, making sure the wires match the original positions.
Step 6: Reinstall Components
- Reinstall the mounting bolts and reconnect the stator wires.
- Reinstall the rotor assembly and secure it with its bolts.
- Reinstall the primary chain and adjust the tension as per the manual.
Step 7: Replace Gaskets
- If needed, replace the cover gasket and any other gaskets that were removed during the process.
- Apply gasket maker to the surfaces as specified in the manual.
Step 8: Reinstall Outer Primary Cover
- Reinstall the outer primary cover and tighten the bolts securely.
Step 9: Add Engine Oil
- Replace the engine oil that was drained during the process.
Step 10: Reconnect Battery
- Reconnect the negative battery terminal.
Step 11: Test and Adjust
- Start the motorcycle and let it run for a few minutes.
- Verify that there are no leaks or unusual noises coming from the primary area.
- Check and adjust the primary chain tension as per the manual.
Remember, this guide is general and may vary depending on your specific model. It's important to follow the instructions in the service manual or seek assistance from a qualified mechanic if you're unsure about any step or encounter difficulties during the process.
