OOPS! Stator Problem.
 

Well I was riding the other day when she quit on me. Found out the battery was low on acid. Anyways, While trouble shooting on the side of the road I accidently pulled the rubber bushing that allows the two wires from the stator to come through the primary case out. So now I have two wires sticking through a 1" x .5" hole and can't get the wires to feed through rubber bushing and back in the hole. I know the rubber bushing should have been molded to the wires which makes this more frustrating. Any ideas on how to get the wires in the bushing and put it back in the opening, trying not to replace the stator.

Try a little lubricant, if that doesn't work then you will have to pull the primary and stator to try and get the wires back where they belong. The wires are molded into the plug when it was manufactured. The connection may have gotten hot causing the bond to weaken, this could indicate additional troubles. Also when you insert the plug into the case it compresses slightly, this would make it harder to re-insert the wires. Take a cover off of the primary and sniff, if you smell something "burnt" then you need to replace the stator. Good luck and I hope this helps.

Thanks brother.

Check to see if the alternator is still putting out voltage, should be somewhere around 45volts AC. Be sure and check for AC at the wires. If it is then personally I'd just plug it in to the regulator and rock on. Might be an oil leak there.

After all Twin Cams make the connection outside the engine.

I could just plug it in and it does all work appropriately, its just that I pulled that rubber seal out and it splashes the oil out the hole.

They get dried out and brittle mainly due to poor contact with the horribly undersized pins they came out with. You can buy just that plug for the stator, but have to take it all out to replace it.

If cosmetics is something you're not concerned about and you're sure the wires have enough insulation so they won't short out, plug it up and smear black RTV silicone around the opening. Let it sit overnight and you're good to go.

PS... good suggestion on smelling for "burnt" if you do, better fix it right. I had one catch fire 30 miles from the shed one day. It's ugly when the primary fluid gets going good ....

Well I just got back from Moonshine's in Poterville with all the gaskets and fluid. I have convinced myself that "Chelsea" (my sled) deserves the proper attention. Do it right the first time. Stator gets ordered today. I guess if you spend three days on it and don't get anywhere, Stop what your trying to do and do it right. Thanks everyone for your input.

Doing it right the first time is always the best way. It saves you from "Rube Goldbreging" it several times. Be sure to use blue loctite on the stator wire hold down and stator screws. Remember which shims go where and put them back in the same order.

Well she's all back together and going with the new stator is the appropriate fix. There's just not enough room in there to try to run the wires through the rubber and then push it through the hole. Its a one man job but have some sort of common sense and enginuity on figuring out how to do things. Get to test driver her in a couple days, for now on duty for a couple days. Total cost on doing it myself = $150.