| Author | Message | ||
     Tarpot |
Hey, everybody! Been a member for a couple of years, since I got my 2000 Blast, read probably three quarters of the site off and on, and have re-jetted my carb, replaced tires and installed a new front isolator all with help from the great advice on this site. But until now I've never had to ask any questions. Hope someone can help! I've had a dead stator for some time. Been riding short trips, but wondering if the bike would start every time I stop got really old, so I finally picked up the parts to replace it. When I got into the primary I found the underlying cause was a couple of disintegrated rotor magnet. So I cleaned everything up and ordered a new rotor to go with the new stator. Meanwhile I've been working through some while-in-there stuff involving the shifter pins, pawl adjustment, chamfering threatener plate for the stator, etc. (per EZ's 3,781 threads on the subject  ) One thing I didn't expect was you have to remove the shift shaft to get to the stator wire cover plate bolt. So the pawl adjustment isn't optional now… My questions: 1. How the hell do you route the new stator wires once they exit out of the primary and toward the back of the bike? How do you fish them through that tiny un-reachable space? Right now it looks like the existing ones go under the starter, through a space that won't allow the plug end to pass. Do you have to remove the air box? What's the trick? 2. Is the #32 (0.116") drill bit for the pawl adjustment a common size? It's not a size a lot of the places around here carry. Is there a more common size that works? For example would a 3mm (0.118") bit be close enough? 3. Ed - in one thread from a couple of years ago you said if the stator went the voltage regulator would probably go soon too. Could you expand on this a little? Thanks in advance for any help. I'm enjoying this work but really want to get it right the first time. Best, Tarpot. | ||
| Gearheaderiko |
Welcome Tarpot! You can order a #32 drill bit if you have the time and it even comes in a blank (not-machined for drilling). While I seem to have lots of them, they are no longer common. I defer to EZ and Swampy to answer the rest! | ||
| Gearheaderiko |
http://www.buydrillbits.com/products/hss/gp2.php?c =DRILLBLANK | ||
| Ezblast |
The stator wires have a small plug fitted onto them, goes through that hole on the case. Experience of mine and others - when the stator goes, the regulator is usually not far behind - you can read all about this on the 1125 board - a bit like the chicken and egg question, except the answer is almost always if one goes so will the other. EZ | ||
| Crackhead |
If you have a large tool supply house like Mc Mastercarr or Granger they will have the #32 bit in stock. I hoping American Sport Bike will stock them so we can send people All's way for everything need to do the shift paw adjustment. | ||
| Gearheaderiko |
Nice work!!! keep'n it Buell | ||
| Tarpot |
Thanks, Erik - great drill site. I actually bit the bullet and ordered the #32 blank from them. Wish I needed more stuff though, as shipping cost much more than the bit! And thanks Ed for your reply re wiring, but I can see where the stator wires go as they leave the stator itself - after all, I'm removing the old one . My confusion, again, is: where do you route the wiring as it goes back to the voltage regulator? On my bike (and I assume this is the original factory installation, though I could be wrong) after the grommet in the wiring, the harness takes a dive under the starter through a very tight passage, and I can't figure out how to snake it through there. In fact it doesn't seem as though the plug end will even fit. So again, is there a trick? Like removing the air box or god forbid the starter? Or did you just run the harness over the starter along the top-left side of the crankcase or something? Thanks, T. | ||
| Ezblast |
Maybe this will help -  EZ | ||
| Tarpot |
I certainly appreciate the picture, but no, it doesn't help. My view of my bike looks *exactly* like this picture at the moment (including oily muffler ) except my shifter shaft / pawl assembly is off now. My old (dead) stator and all its wiring is still in place, and it's easy to see the full routing, starting at the stator and going all the way back to the plug connection to the voltage regulator. My confusion: I can't see how anyone who is replacing a stator can possibly thread the new wiring, once you get *outside* the primary, back to the VR through the same places as it is now. The narrow crevices between components simply seem too narrow for the plug end of the wiring to fit through. Does this make sense? I thought of tying a pull-string to the old wiring as I withdraw it back-to-front through the hole, so I can then use the string to fish the new wiring through the same path as the old. But the plug gets stuck. So I guess I either need to remove something I haven't, like the air box or the starter, or else people replacing stators just don't run the wiring lead to the VR in the same place as it came from the factory. The Question: To anyone who has replaced a stator: How did you route the wiring - once it gets *outside* the primary - back to the the VR? What am I missing? What is the trick? Thanks again - I really appreciate the help. Sorry if I'm belaboring this! } | ||
| Ezblast |
Actually I did the pull string trick as you described - it will work out, don't stress it. If I can do it, I'm sure you can do it. The plug is supposed to get stuck - lol EZ (Message edited by ezblast on June 25, 2011) | ||
| Swampy |
I'm looking, thinking we have a parallel thread going on at this moment over in the knowledge vault/engines/primary....LOL | ||
| Ezblast |
Yeah - it is a bit like de jevue - lol EZ | ||
| Swampy |
Deja Vu? As in 100 beautiful girls and 3 ugly ones? True story, After over a year of storing 4 ratty couches in MY garage taking up valuable space(my wife promised me it would only be until April 15th) Basement Bobby finally gets around to putting the couches up on craigslist, we got rid of all of the couches but the nastiest one of the four. We were all sitting out on the back deck chilling one evening when he gets a call from someone wondering if there were any couches still available, and since there was he eagerly gave out the address and we commenced chilling. About a half hour later an old rusty(Rust, for you guys that live in one of those idelic places where it does not snow so there is no need to dump salt mined from under the the vast wasteland called Detroit, this thing had holes in it you could toss a puppy through) Ford two wheel drive extended cab 8 foot box pickup truck painted as beige as my friend Al who just happened to be chilling with us on the deck. Out jumps some little girl all of about 17, blue pink and blonde hair, in a holey tee with shorts, multiple tattoos and piercings on her face and body including a set of angle/devil wings covering her back. Al spits his beer, Bobby puts on his best salesman, and I jump up to greet her. Anyways, I back her truck up the driveway because she can't do it and as we are loading the last couch into the truck hoping she doesnt get too good of a smell of it, she starts asking us about the apartments on either side of the neighborhood, emphasis on "Hood" As it turns out we find out that she lived with her parents on the other side of the swamp that I live at in Eureka. We find out her name is Trixie and is a dancer at the Deja Vu in Lansing. So I just smile and ask her "Oh yeah? How bout some free passes?" And she just says come to the back entrance and ask for her. Now I told you that to tell you this..... Earlier this year, sometime right after the snow melt but still cold, I get a call from the Litte Kid, it is like 2:30 in the morning and he is all shook up and wants a ride home from the party he was at because there was some fight there and some chick wouldn't let him leave and jumped on his back and bit him and he didn't have his glasses or car keys, they were back at the party. I got an idea where he was and told him to find a safe place out of sight so the police wouldn't find him and I would be there in 30 minutes. The wife and I get there, find him and he is all shook up because he didn't know where his keys or glasses were. He mentioned that one of his friends, Drew, was there at the party so I called Drew up and his friend Drew told me that the party was getting pretty stupid and all drama so he left also and started walking back to Lansing about 25 miles away. So I asked him if he would go back to the party and get the Little Kids glasses and keys and I would give him a ride home. He said sure. We pick up Drew and he gets back into the apartment and brings back the glasses and keys and Drew and I hop in the Little Kids car and drive back home. So we start talking about stuff and some how the discussion comes around to Trixie. Low and behold Drew says, that Trixie was his exgirlfriend and they broke up recently so he called her up and they started talking about me like we were old friends. The moral of the story is, just like Walt Disney says "It's a small world after all" So all I have left in the garage is my garage stuff, and Basement Bobbys ancient projection TV and some enormous Basketball hoop game, taking up places to park motorcycles, she didn't say what April 15th. | ||
| Imblasted |
I am from grand rapids and i know what deja vu is. i also dated a girl that was almost exactly like trixie except she didn't dance at a strip club. she was tiny crazy and tattoo'd. but thats what my bike is about to look like too. o its not your bike swampy. o well | ||
| Tarpot |
Okay, so the new stator wiring is in place. I gave up on the pull string because all it did was get the plug end wedged tighter in the dark crevice between the case, starter and rear isolator. The trick seems to be to pull the air box, so you have room for your fingers, a long shank screwdriver and a flashlight to see, poke and pull the wire where it needs to go. Definitely a pain in the a**. All the other "while-in-there" stuff is done, so now just waiting for the new rotor to arrive. May be back for help on adjusting the clutch Tarpot | ||
| Ezblast |
LOL - thats why it was so hard for you - you have an air box - lost mine long ago - lol EZ |
