Hey kids....quick question. Anyone ever replace the stator on a 650 unit motor? I'm trying to figure out what keeps the wires from getting wrapped up in the primary chain. There seems to be enough clearance...but just barely. Also, I noticed in an old manual I have, an illistration shows the wires coming from the stator on the outside, but the one I took off the bike the wires where facing inside. Does it really matter which way the stator sits over the alternator? Any help is appreciated. Thanks!
The wires are kept off the primary chain by the stiffness of the wires, and, IIRC, one strap clamp. The way it's mounted has nothing to do with the function, nor does it matter if the stator is encapsulated or open. Put it on, make sure the wires won't touch the chain however you need to, and enjoy. Cosmo
After everythng is tightened down, run an .008 feeler gage around the stator, you need that much clearance. Of course you've checked that your alternator studs are all straight and not bent from past crashes. If you cant get the clearance, back off the nuts and rap the thing a few times with a soft lead hammer, in the direction you need to get clearance. Then tighten up. In some cases you can take .004 or so off the rotor in a lathe but you shouldn't need to. Seal the wire opening with something so rain water doesn't contaminate the primary case. ATF is a high pressure type lube, works good in the primary...keeps the cluth plates from stickin together when you start in the morning
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