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Old 27th September 2014
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tigercreek tigercreek is offline
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Default 2000 883 Stator Replacement

I didn't start out replacing my stator with a how-to in mind, but I took some pictures along the way and ran into a few things that would have been nice to have the answer to before I started.
Obviously the first thing you'll need to do is remove your primary cover - after draining. Get it to this point and you're ready to remove all of the allen bolts and pull it off. Don't forget to loosen the primary chain tensioner before pulling.
Once pulled this is what you'll be looking at.

I was told that it was possible to perform the replacement without removing the clutch. I don't believe it since there isn't enough slack in the primary chain. This is where I wasted a lot of time. Do yourself a favor and pull them both.
First use a 1 1/8" socket on the sprocket - counter clockwise to loosen. I used an impact since I did not have the block that keeps the chain/sprocket from turning.

Next you will need large snap ring pliers to remove the clutch adjustment housing so you can get to the nut. It comes out as a single unit. Then you can access the 1 3/16" nut which will need to be turned clockwise to remove. Again, I used the impact wrench.

Then slide the clutch pack out (it does not have to come all of the way off) and then pull the sprocket and stator cover off to expose the stator. Magnets are holding it on.

Next remove the four Allen bolts holding it in place and the two 5/16 hex head bolts holding the wiring in place. Then come in from the outside of the grommet plug and tap it through with a punch or long screwdriver.

Now you're ready to pull all of the old cable through. First cut all of the wire ties holding it to the frame. Then before you make the last pull before getting the plug from the bottom to the top of the motor do yourself a HUGE favor and wrap some wire around it so will will have something to guide the new cable back through the motor/covers.

After that pull it through the case, replace your stator and button it back up. After removal I found that the cause of my failure was bare wires where the stator cable exited the housing.

I am guessing the short was bad enough to cause my rectifier to fail because it was dead as well when I buttoned mine back up. Fortunately I had a spare.
After all of this I am considering putting a small voltmeter on the bike to help me monitor voltage. Nothing quite like being a long ways from home with a dead bike.



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Old 27th September 2014
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Don't forget to replace the 4 stator bolts whenever you do this. they come from harley with locpatch on them and are one time use..
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