So about a month ago I was seeing a lot of guys on here asking about their stators and I was thinking that while I was changing my charging system out on my rigid that I would do a little tech article how to with some tricks built in and shoot some pics. My other bike is a Dyna and the inner workings of the primary are a little different but this will give you the overall. Your parts may look a little different but I think this will work. Also my old seat spring were causing my battery issues so I took the time to weld on some seat spring mounts from lowbrow instead of using my old frenched in ones. Problem fixed.

1. Loosen your slack (all of it) out of your clutch cable.
2. Disconnect the battery and drain the primary fluid.
3. Unbolt the voltage regulator from wherever yours is and disconnect the wires. Mine run under my tank.

4. remove the outer primary cover this is what you will see


5. Put the bike in fifth gear
6. I made a tool (black steel jam bar) with a cut off wheel and angle grinder to place in between the teeth on the compensator sprocket and the clutch hun out of flat steel. Also you will need a impact wrench to get the two parts off to get at the stator. Here is a tip. Jims makes the two oversized socket to use that cost over a hundred buck. For less than ten I got the same sized ones at harbour freight.



7. Remove the nut from the primary chain adjuster.
8. Remove the circlip and clutch adjuster


9. Use your impact wrench (you cannot loosed this with a regular socket wrench) and loosen all the way the compensator sprocket assembly.

10. With the impact wrench remove the clutch hub nut. It is reverse thread!!!!!!!!!

11. Now pull the entire assembly and chain off the splined shafts.

12. You will now be looking at this. Inspect it while it is off. Also check all your bolt securing tabs too for breakage. Replace as necessary.


13. use two small allen wrenched to put in the holes of the stator magnet to remove. DO NOT loose or mix up the washers. One on the outside and one on the inside.

14. Remove the four stator bolts.

15. Remove the little plastic stator wire retainer toward the top left of the stator

16. Now don't worry about hurting the stator cuase it is already fubared right. Either cut the wires and get the plug out or pull it out.



17. Now put the new stator back in. The plug is a bitch to get through the case but I recommend a combination of dish soap and silicone spray. Reassemble and make sure you adjust your primary adjuster so it won't hit your primary at the tightest spot. To readjust your clutch move the bolt in until you just barely feel it catch and then back it out a quarter to half tun and tighten the nut. Fill your primary and let the slack out of the cable.

oh and these are my welded seat mounts. yeah I know my mig welder was ****ing up.

http://www.youtube.com/watch?v=rRWr7ff8Xrk

 

great write up!

 

thanks man

 

good write up and nice rigid, also you should have upgraded the primary tensioner while you were in there

 

yeah I have it on my 06 superglide and it is nice but I like the simplicity of that one on my rigid. That is until I find a smoking deal on one from one of my buddies. Thanks for the nice compliment.

 

All of this tech for you guys and now I just realized that my helper who is a 18 year old friend of my sister in law ( I am only 27). I gave home one task to tighten up the primary cover and the ******** stripped one out. Well now to ponder getting a new black inner primary housing off of eBay or helicoil it. Helicoiling it is cheaper but will probably just make me pissed off. An I have ripped the primary apart more times in the past year than I care to say so I am not looking forward to all those tabs and removing it. Ahhhhhhhhhhhhh

 

I have an extra automatic primary tensioner form my 06 Streetbob 88 incher/6 speed layin around in perfect condition. If you need it its yours $25.00 shipped, since you gotta tear into it again anyways. I think I even have some new sealing bolts and a spacer gasket also. $35 shipped for it all.