Replacing Stator and Rotor and then!!!!!!!!!!!!!!!!!!!!!!!

[Sharkey62]

What's going everyone, got a new problem. I have been working on replacing my stator and rotor but after pulling the clutch basket off, oil from the transmission is leaking through a rubber seal on the inner primary. Is this normal or is the seal compromised or could there be other problems on the other side of the primary.

 

[HMAN]

Replace the seal. Not a major deal. Give HDM a call.

 

[Sharkey62]

That what I figured. Is it the same as HD

 

[Mr. Wright]

The seal seals around the back side of the clutch basket. The oil in the transmission is higher than the lip on the seal, so when you pull the clutch basket yes the oil will leak out. No that is not the same seal. And just an FYI do not have to remove the clutch basket to remove the front pulley to change out a stator

 

[Sharkey62]

The seal seals around the back side of the clutch basket. The oil in the transmission is higher than the lip on the seal, so when you pull the clutch basket yes the oil will leak out. No that is not the same seal. And just an FYI do not have to remove the clutch basket to remove the front pulley to change out a stator

I tried the other way without pulling the inner primary. Local motorcycle shop recommended it since its easier to get the plug in thru the casing. And thanks for the comment on the seal. I figured it wasn't an issue since the oil didn't start flowing until I removed the clutch basket and the bike is on the kickstand. Thanks

 

[Jersey Big Mike]

I tried the other way without pulling the inner primary. Local motorcycle shop recommended it since its easier to get the plug in thru the casing. And thanks for the comment on the seal. I figured it wasn't an issue since the oil didn't start flowing until I removed the clutch basket and the bike is on the kickstand. Thanks

You do not have to remove the inner primary to do this.

 

[Mr. Wright]

If you look closely you'll see that there is a set screw right on the side of that plug. If you back that set screw out the plug will pull right out. Then put a little silicone around the plug and it'll push right back in. Then just tighten the set screw till it's flush again

 

[Mr. Wright]

I tried the other way without pulling the inner primary. Local motorcycle shop recommended it since its easier to get the plug in thru the casing. And thanks for the comment on the seal. I figured it wasn't an issue since the oil didn't start flowing until I removed the clutch basket and the bike is on the kickstand. Thanks

Also, I'm not being a smart-ass, but these are not Harleys. Ask your questions on here not the Harley shops. There's been more Dogs screwed up in Harley shops than I can count.

 

[Sharkey62]

If you look closely you'll see that there is a set screw right on the side of that plug. If you back that set screw out the plug will pull right out. Then put a little silicone around the plug and it'll push right back in. Then just tighten the set screw till it's flush again

I 've backed the screw and got the old one out, I tried the other way and damaged a brand new stator. So that's when I went to the shop for info. I appreciate the link to the manuals, I'm sure they will be great help. And I also appreciate you thoughts on where I should get info from. I'm kind of new at this.

 

[Sharkey62]

Good evening everyone, I have been working on replacing my stator and rotor. Tried to put the new rotor in but according to a well known Bigdog expert stated that I need to file down the knobs inside of the primary to allow the new rotor to be installed. I also spoke with a tech in Wichita, Ks for Bigdog and he stated to remove the inner primary which is the route I am heading. I have removed all the bolts from inside and the outside of the inner primary to include the 2 on the starter. when I tugged on the inner primary to remove it, nothing budged. So am I missing something or do I need brute force to pull the inner primary.

 

[SKOGDOG]

This should help. Follow lower right directions as needed to remove the ten bolts……..not a bad idea to replace the rubber o-rings while it’s easy…..torque to specs and be careful of the pesky ring on the outer primary. Don’t bash it but maybe tap with a rubber hammer. Should pop off.

 

[Mickmorris]

Good evening everyone, I have been working on replacing my stator and rotor. Tried to put the new rotor in but according to a well known Bigdog expert stated that I need to file down the knobs inside of the primary to allow the new rotor to be installed. I also spoke with a tech in Wichita, Ks for Bigdog and he stated to remove the inner primary which is the route I am heading. I have removed all the bolts from inside and the outside of the inner primary to include the 2 on the starter. when I tugged on the inner primary to remove it, nothing budged. So am I missing something or do I need brute force to pull the inner primary.

Ok so I had the same problem when I did mine. Low and behold there is one more bolt on the bottom that you have to get to from the right side of the bike. Might have your ground wire connected to it. This might be the reason. As soon as I removed it the primary cover came right off.

 

[awg]

While we are on this subject, I to will be needing to replace my stator in the near future. Couple of questions for now. Is the bolt on the cam (or rotor) lefty loosey? And what size bolt is it? And will it break loose with a breaker bar? I read that they can be very hard to loosen.

 

[Jwooky]

I did a write up a while back on the modifications needed for an aftermarket rotor /stator.

Charging stator /rotor issue

Bike was not charging. Checked for AC voltage at stator and it was 0. Replaced the stator with new compufire stator and checked for AC voltage at stator and it was still zero. . WTF? Can rotors go bad? Their is nothing left?? The rotor was still magnetic. I don’t get it.

www.bigdogbiker.com

 

[awg]

Thank You.

 

[Sharkey62]

While we are on this subject, I to will be needing to replace my stator in the near future. Couple of questions for now. Is the bolt on the cam (or rotor) lefty loosey? And what size bolt is it? And will it break loose with a breaker bar? I read that they can be very hard to loosen.

Lefty loose for the rotor and right for the clutch pack. The socket i used was a 33mm impact. Due to the lock tight on the nut. I put more torque on the nut to break it loose the was able to break it loose with lefty loosey. And I did get the inner primary off today. Just firm yank and it came off. The new rotor is in place and tomorrow I will be reassembling. If you need anything else don't hesitate to post. And by the way there was no grounding strap like you had. Thanks for your post.

 

[Sharkey62]

is there a torque specification for the starter

 

[Rottweiler]

Lots of good information here.

Dropbox

www.dropbox.com

 

[Sharkey62]

Well the Dog went for walk today. New stator and rotor and she runs like a champ. The voltage regulator will be done later but for now the voltage output in good to go.