I'm am putting a new stator in my engine and I can't get the stator plug to slide into the case hole so the voltage regulator can plug into it from the outside. I've WD-40'd the plug and hole. Then forcefully pushed the plug with a pliers but it is still barely in the hole. I don't want to get too rough and damage something in the process.

I would appreciate it if someone would fill me in on how to get it installed without messing things up.

Thanks in advance for your help!

 

Is this an aftermarket or OEM stator you're installing? The last OEM stator I installed, the plug was so loose it took copious quantities of RTV just to keep it from leaking right away.

 

It is an aftermarket one made by Compufire. Thanks.

 

Try using a 1/4" extension to shove it into place.

 

Instead of WD-40 which actually isn't a lubricant, use WD-40 Silicone lubricant.

Be careful because everything it gets on will be slick for a while.

 

Slather this on the plug...it will slip right in with minimal force...seriously-it works!

http://www.cvs.com/shop/beauty/skin-...prodid-1015638

 

I have used some black (rtv) silicone sealer to get them in. It adds a sealer to the plug.

Good luck WP

 

What year bike?


If you're replacing a 22 amp alternator with a 30 amp setup, you will need to trim the ribs on the stator plug, else you'll never get it thru the hole. And yes, a silicone lube is highly recommended. I've done a lot of them like that.
Take care to not compromise the wires while pushing on the plug.

 

I was able to get the stator plug installed on my bike. As suggested I slathered it with glycerin and shoved it in the hole. Still needed to persuade it by using a pliers to wiggle and press it through the hole with some force. But in about 5 minutes or so it was a done deal.

Thanks for the help!

 

Good to hear you got it

WP