I had a similar problem on my '03 XL, the stator had gone.

 

Bump for a great thread

 

Yep. Bookmarked this one!!

 

Bump again...should be a sticky

 

Great Post!!! inspired me to do this job myself. Question how do you get the wires out of the stator plug housing? I pulled the inner blue spacer but cannot figure out how to get this a part without breaking the plastic housing. I know you have to reuse this on the new stator. Also is the clutch hub nut 1 1/4 or 1 3/16??? I have seen both numbers used in posts.

Thanks again for all your help.

Rusty

 

bump, think mine may be going out, what a great write up!

 

Doug, Thanks for an excellant article. I had a leaking shifter seal along with leaking output shaft seal. 2002 FLHT 66,000 miles. With your article and HD manual I am hoping to finish today. Made a primary locking tool from some delrin plastic at work, made the new kind recommended. A flat stick one inch wide and 7.5" long to go in between the sockets. Put's less stess on shafts. Also made an output shaft socket out of a 1 7/8 socket and black pipe 2 1/2" dia. Cut the sprocket in half and weld to ends of pipe. Hope to back on the road soon.
Jambriwal

 

Subscribed. I don't have a stator issue with my '92 Fat Boy, but I am in the process of trying to pull the inner primary off and the way he made the lock out tool was just what I needed. Already built a lock out! Thanks!

 

WhT size to take comphensator bolt off

 

Thanks for the great tutorial! Followed your instructions except I skipped taking off the inner primary cover, and my bike is now running properly again!