Stator looks pretty good except for that area with that looks like hardened silicone or burned goop. Is this normal or does it need replacing?

 

If it doesn't stink like burnt real bad it's probably ok, the only real way to tell is to run it & check output. Was it charging before you pulled it apart?

 

It's done. Get a Cycle Electric.

 

I can only assume your in there because you have been having issues. Replace it. Even of you haven't been having issues you probably will soon. It would suck to have to rip it down again after a month or so of riding.

 

Haven't had any charging issues. Did have a broken inner primary bolt that needed extracting and a leak from the stator plug.

 

What year bike & how many miles?

 

 

As mentioned in this post ^. Even though you don't have charging issues at this moment, that stator needs to be replaced. OR, you can wait for it fail (and it won't be long) and you can buy a battery and possibly a regulator/rectifier; then you can take it all apart to where you are right now.

 

Well, it looks nasty, but, it also looks like it didn't come from the stator. If that's the case, why condemn the stator? (If it did come from the stator, then obviously there's something wrong with it.)

[Edit] Where did this bit go?

 

It looks like that was riveted on. That pic is of my 08 Fat Bob, so you're stator might be different since your bike is newer. To tell you the truth that's the first time noticed that. The new stator that I installed from Cycle Electric didn't have that.