[slickwill]

Thanks to a girl at school knocking over my bike I recently replaced a scratched up stator cover.


The manual for my 2002 F4i calls it an alternator. I'll call it a stator since it is shorter and many people refer to it that way.


1. Remove left fairing.

2. Drain the oil, try not to drop you filter in to the pan and splash oil everywhere like I did.


3. For an F4i, unclip the idle adjuster and push it out of the way.


4. Remove the nine cover bolts. 8mm socket.

5. Gently pull the cover off. Don't use force. You might have to tap it a bit with the heel of your hand to break the seal. You can use the three tabs to actually get a hold on the cover to pull. Work all the way around the cover to make sure that the seal is broken all the way around. The stator is magnetically attracted to the flywheel so you have to use a bit of force when you pull the cover. However there is a small dowel still holding the cover in place so you have to pull absolutely straight out. If it sticks just back up and start again. It takes just the right "touch."


6. I tied the cover to the frame so that it could hang without putting any pressure on the stator wire.


7. Gently tug on the rubber grommet that contains the stator wires (blue arrow) to break it through the old gasket, remove the wire clip bolt and wire clip (red circle, red arrow), then remove the four stator bolts (black circle).


8. If you are reusing your cover you need to clean the old gasket from the cover, brake cleaner, or denatured alcohol works for this. Otherwise just set it aside like I did and hang the stator somewhere.


9. Remove the dowel and clean the old sealant from the points where the crankcase halves come together, I used denatured alcohol and my thumbnail. Save the dowel unless you purchased a new one like I did.


10. From here on out the last part kind of needs to flow into one big step all at once. I was really wishing for a third hand for part of this. Add sealant on the crankcase at the two points that you cleaned it off of earlier, it only takes a bit, I used Blue RTV.





More to come, have to go.

[emsnyder]

I have to replace the crankcase cover on my 919. That's essentially the right side of this same set of steps, and less involved, from what I can see. I think its just 3 screws and a gasket, and try to recover the oil I lose in the process?

[.OrgOwner]

Nice write up!

[slickwill]

Originally Posted by .OrgOwner

Nice write up!

Funny, I actually forgot about it. It's only half done, I ran out of time and had to go to class when I was writing it. I'll have to find some free time and get the directions for putting it back together finished.

[jetdavdub]

bump better finish your writeup LOL

[akraut]

I took a look at these instructions, and reassembly is the reverse of disassembly, BUT... make sure you double check the starter gear, otherwise you'll do like I did and have to take it apart all over again.

[slickwill]

If you are just doing the stator you shouldn't even touch the starter gear. You should only have to worry about the starter gear if you pull the flywheel also?

[akraut]

The gear and the pin it rides on are fairly loose without the cover and if the gear isn't completely pushed back in just before you put the cover on, it won't properly engage the starter motor.

When I get down to the parts store and empty the old oil, I'll redrain, disassemble, and take some photos to post.

[breimers]

Hey slickwill, thanks for taking the time to do the article. Great job!

[bladeracer]

Originally Posted by slickwill

The manual for my 2002 F4i calls it an alternator. I'll call it a stator since it is shorter and many people refer to it that way.

To clarify, the alternator is the stator and the rotor in combination to produce alternating current. The stator is merely the coil part of it.

[slickwill]

Okay, so almost a year later I'll finally finish the write up.

10. continued,
At this point bolt your stator back in to the stator cover. Then replace the wire clip and wire clip bolt. Check the manual for torque specs (around 9ft/lbs I think, but please check, it's been awhile) for all of the stator bolts.

11. Now put the dowel pin back in the stator cover. Then put just a small dab of RTV, Yamabond, whatever, at each spot where you had to clean the sealant before. Just a bit. You are covering the two spots where the case halves come together (see pics in step 9). Now very carefully put a small amount of sealant around the rubber grommet on the stator wires (red arrow). Then push it into place in the stator cover and carefully put a new gasket into place. It's very tricky keeping the wire grommet from pulling out of place and making a mess. If you have a third hand use it (or her) to hold the grommet in place and then slide the cover back in to place on the bike. Put your bolts back in and slowly torque them down in a criss cross pattern in steps. Just a bit at a time until they are all to spec. More than one person I know has split their new stator cover from being over agressive while torquing them down. They are soft aluminum, not very strong.



12. Refill with oil. I did a full oil change with mine, if you do the same then make sure you replace the oil filter as well. Word on the street is that you can lean your bike against the wall to save the oil, I've heard it from a few people. I can't imagine why anyone would want to go to all this work and not take the extra 60 seconds to refill with fresh oil, seems really hillbilly to me but if you want to give it a try then have at it.

13. Put everything else back together. Fairings, vent hoses, idle screw, anything else that got moved.

14. Take a look at the finished product and recheck your work.

[cbr_df]

mmmm sorry to go against your post but is not necessary to drain the oil. if you put a blanket(thick one) on the bike and lean the bike against a wall you dont need to drain the oil at all. just a suggestion.

[slickwill]

Originally Posted by cbr_df

mmmm sorry to go against your post but is not necessary to drain the oil. if you put a blanket(thick one) on the bike and lean the bike against a wall you dont need to drain the oil at all. just a suggestion.

Umm, read step #12 of my directions...but hey, hillbilly's aren't only in Kentucky.

[bassdb]

Thanks for the write up! Good Job. I am doing mine this weekend.