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EVO: Electrical System - Sub-02B

91-03 Stator Replacement

This is not intended to replace the service manual but rather to explain more in depth with pics.

The stator is in the primary compartment behind the engine sprocket.
You'll have to remove the primary cover, engine sprocket *and* the clutch basket to access the stator.
Before removing the primary cover, you'll need to remove the shift lever bracket (or mid foot pedal bracket if applicable), linkage and derby cover.
Drain the primary fluid, loosen or remove the clutch cable and loosen the primary chain adjuster.

Before removing the primary cover

Remove shift lever.
1) 2) 3)

The clutch cable is best removed from the cover. However, for this application, you could simply leave it on and hang the cover from the bike once removed.
To remove the cable from the cover, remove the derby cover to gain access to the clutch ramp.
4) 5) 6)

Loosen the clutch cable.
7) 8) 9)

Loosen the primary cover screws to allow oil to drain in a bucket / catch pan.
Some of the screws are different lengths and need to be placed back in their respective places.
You can use a piece of cardboard with a sketch drawn of the cover as to where the bolts go.
You can punch the holes with a screwdriver, insert the screws for holding and it makes reassembly less of a headache.

10) 11)

Loosening the primary chain adjuster takes the pressure off the primary chain from the cover.

Removing the primary cover

12)

Removing the engine sprocket / clutch basket

A reversible impact wrench has been used successfully to remove both the engine sprocket and the clutch basket nut.
However, it's been debatable whether you can accurately install them back to proper torque without using a torque wrench instead.
However, you remove the nuts, use regular six-sided sockets.
They are less likely to slip and round off the edges of the nuts. Impact-type sockets are likely too thick to fit.

Normally when loosening or tightening these nuts, you will need to lock the hub & sprocket - Do not wedge the chain.
You can buy a primary locking tool (bar) or use a closed 4“ BRASS hinge as a wedge. Place the wedge so as not to put pressure on the shifter shaft
There are also several 4 and 5 speed primary locking tool examples in the tool section.
A closed 4” BRASS hinge also works well to lock the sprockets and then you can use a pull bar and sockets / socket wrench.

13) 14) 15)

The engine sprocket and clutch hub should be removed as one unit.
Once the sprocket and clutch basket is removed, you can gain access to the mounting screws for the stator.

16)

Removing the stator

1) , 2) , 3) , 4) , 5) , 6)
photo by Hippysmack
7) , 8) , 9) , 11)
10) , 12) , 13) , 14) , 16) , 17) , 18) , 19) , 20)
photo by tigercreek of the XLFORUM http://xlforum.net/forums/showthread.php?t=1823130
15)
photo by Scuba10jdl of the XLFORUM http://xlforum.net/forums/showthread.php?t=53268
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