Installing a new stator in a 1998 Dyna Wide Glide FXDWG and I was able to get everything disassembled with no issues. Now I'm trying to get the new stator in but it won't slide in. I checked to make sure the stator part # was correct and it appears it should fit. I tried using assembly lube but that didn't work either. I figured I'd ask here to see if anyone had any tips. I'm about ready to just use a mallet. I won't... but I want to. Thanks in advance!

 

 

The 97-98 Dyna Factory Service Manual says, "It is not necessary to remove the inner primary chaincase to remove the alternator." I removed the primary cover, primary drive and clutch per the service manual. Other than that I removed the old stator and can't get the new stator to seat all they way back in.

 

My guess is I need to source another stator. There is a difference of .01" between the two.


Old stator 2.76"




New stator 2.75"

 

 

I'm sure I'm putting it in the correct way. I was able to get it late this morning. Making sure I was flush and applying pressure evenly I noticed the stator appeared to not be a perfect circle. I was able to run a a few passes with a Dremel sanding bit on the inside of the stator and get it installed. I also took it off to see if it would come off as easy as the original and it was a little tighter but a few wiggles and it came off. I reassembled as far as I could and now have to wait on a primary chain to arrive before buttoning the whole thing back up.

Glad I can finally move on to the other things my buddy wants done. It was just supposed to be a simple stator replacement and it turned into stator, regulator, primary chain, and a few other things like tires and saddlebags. And, after seeing everything else I plan to go thru all the electrical and wear components just to make sure everything is looking ok. Especially since when I got my hands on it someone had changed the primary oil, the chain tensioner shoe, the clutch cover gasket, but left a weeping primary cover gasket, didn't even use the inspection cover gasket and inspection screw gaskets, and then sold it. Luckily the stator burnt up, otherwise it could be a lot worse. Some people's kids...