Installing the New Stator

Turn the generator cover upside down (resting it on some clean shop towels or other protective layer). See photo above.

Remove the single bolt for the stator wire bracket--noting how it is positioned, for reassembly referrence. Next, use your fingers to wiggle, and pull loose, the two rubber oil seals for the stator wires. See photo below.

Use a T-30 Torx wrench to remove the stator from the cover. The three bolts are on with Loctite so they may not come off easily. Tip: If you must use heat to loosen the Loctite, be careful you don’t melt any wiring coatings. You may have to replace the bolts if they don’t come out without bunging up the heads. See the Parts section for part description.

Now is a good time to clean the generator cover gasket surfaces of old gasket remnants. Do this for the gasket surface of the engine case, as well as the generator cover. Be sure to wipe up any particles that may fall in. Be sure you clean off all silicone remnants from the oil seals and cover, too.

If you separated the oil delivery pipe from the generator cover for some reason, bolt them back together. Be sure both ends of the oil delivery pipe have their O-rings installed.

Next, bolt the new stator assembly into the inside of the generator cover. Torque the torx bolts to 5.1 ft-lbs, which is 61.2 in-lbs--not too tight. Be sure to use blue Loctite on the bolt threads.

If you are installing an ElectroSport stator, you might only be able to match two of the bolt holes. I have not seen this, but I have read that it was the case, at least for earlier units from ElectroSport.

Now apply RTV (silicone) gasket maker to the two, rubber, oil seals and push them in to place. See photo above. Do not wait for the gasket maker to dry. Install the generator cover before the gasket maker has cured. The assembled cover will hold the oil seals tightly in place while the gasket maker dries.

Before installing the generator cover, re-install the stator wire bracket inside the generator cover. See prior photo above.

Insert the two alignment dowels for the generator cover into the engine case. Then slip a new gasket over the dowels.

Tip: The generator cover is magnetized to the generator rotor. As soon as you begin installing the cover, it will be sucked in by magnetic force.

Bolt and torque the generator cover on, using 7.2 ft-lbs, which is 86.4 in-lbs. The long bolt nearest the oil delivery tube has a copper or aluminum washer. I recommend you install a new washer at this point. I didn't, and it leaked.

Bolt and torque the oil-delivery-pipe back into its hole in the right-side of the engine case, using 7.2 ft-lbs of torque. Again, be sure it has its O-ring installed.

Now run the stator wires back toward the corrugated wiring harness. Tie and tape the new stator wires just like you did for the old wires. Help get the process started by pointing the connector into the corrugated tube so that it won’t get hung up within. Carefully pull the string (and new wires) up through the tube to the point of connection under the side-cover area, near the bike’s center.

If you are installing a Yamaha stator, smear some dielectric grease into the contact points of both connectors and then connect them. If you are installing an ElectroSport stator, you will have to cut the Yamaha connector from the old stator, and solder it to the new one.

Alternatively, you could cut the stator connector from the bike, and connect the new stator with the generic connectors provided with the ElectroSport stator. Then smear some dielectric grease into the contact points of both connectors and then connect them.