Has any one had there stator rewound? A new stator is going to cost me about $300 Canadian, so I'm looking into rewinding it.

 

There are a few on here that have rewound their own.

 

I wonder how difficult it would be to rewind it my self?

 

There's a place here called LaFountain Generator that "rewinds" alternators. I don't see why they can't do stators. Very affordable.

 

You don't have to spend big money on a stator.Check this out....... http://cgi.ebay.com/CHARGING-SYSTEM-...item53e4c46068

 

Careful, That sale price Stator is only 22 amps. That was standard in 1988 and older, however today most bikes start at 32 amp, and up. You must have a matching rotor for the correct stator, and the matching voltage regulator. I believe your '06 is 38 amps.

I bought an H/D kit with all 3 parts for a little over $200 and upgraded my 22 amp to 32 amp to help maintain the battery with additional secondary running and braking lights.

It's quite the task to tear down the primary, including removal of the compensator, primary gear, primary chain and often the entire clutch (pack) must come out to get to the rotor / stator assembly.

And always use new hardware for securing the stator. H/D supplies bolts with a compound on them like loctite to prevent loosening. The old bolts were torqued and simply removing them is concern that re-torquing them will damage them and they will not hold, might even brake while in use ... don't want that for the cost of the bolts, which came with my "upgrade kit".

Oh and to the question how hard is it to rebuild the stator... Personally I would not risk it at all. Unless it's done professionally you have a lot of (unknown) concerns in rebuilding it yourself ... there's no kit for that.

 

The stator on ebay is listed to fit up to 2006. 22 amp is correct for those years. It was with the fuel injection in 2007 that the stator capacity was increased, I believe to 33 amps. Anyway, 22 amps will work up to 2006.

 

+3.

 

I feel your pain....
I did a stator, regulator and battery....and not in that order. Cheapest first.