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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Electrical - Battery, Charg Sys, Lights, Switches, Sensors & Guages » XB 3 phase Stator Issues « Previous Next »

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Al_lighton
Posted on Wednesday, October 10, 2012 - 11:32 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

We have seen a number of BRAND NEW stator failures on the 29971-02YA part. There is a design/manufacturing defect in a bunch of them that have been sold in the the past year.

The stator that we have been selling IS the OEM current revision part (29971-02YA), and HD seems to be aware of the issue but hasnít offered any solutions or clarifications. The later 29971-02YA stators added a wire dressing plastic part that may be a little too thick, and there is potential interference between the wire keeper and/or that keepers retaining rivet, and the sprocket mounting bolt heads on the rotor.

See the pictures below of the earlier 29971-02Y (wires dressed in goop) and the current rev 29971-02YA (wires dressed in a keeper). Also shown is a picture of one that has been damaged by the interference. The metal rivet that holds the plastic wire keeper onto the stator is the main interference point. I am aware of several failures that have occurred, but they donít seem to be universal.


29971-02Y


29971-02YA


29971-02YA damaged


If you get one from us or elsewhere, youíll want to do a trial fit and check for clearance there prior to buttoning it all up, and may need to dress that wire keeper a bit if there is some interference. Note that HD will warranty a stator that has the problem, but will NOT warranty all the other parts and such used during the installation, nor will they pay for any costs you may incur should you lose your charging system and have to get your bike towed home. So you really want to make sure that you do NOT have the problem prior to buttoning up your primary with this stator.

We donít have an alternative stator to offer at this time. This is the OEM part, so HD really needs to fix it. But it may not get fixed in a timeframe acceptable to you should your stator fail today.

From what weíve been able to determine, the plastic keeper is thicker on some than on others. If it were me, Iíd probably remove that wire keeper and pot the wires in place with epoxy like on the earlier revision stator. The only issue with this is that doing this will likely invalidate their warranty if you do this. So itís a bit of a catch22. I know if it were me installing one on my own bike, I would clay up the fit and remove that keeper if I found any interference or even only marginal clearance.

There is some discussion of this here: http://www.buellxb.com/Buell-XB-Forum/Do-It-Yourself-Buell-Mods/How-toDIY-XB-stator-replacement . It appears that some folks have ground down the heads on the rotor bolts to get the clearance. That would NOT be the way I would do it, those are grade 8 bolts and probably shouldnít be weakened like that.

Al
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Bud
Posted on Monday, October 22, 2012 - 09:26 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

we had 2 so far

and some time apart from bought issues

very annoying.

we did remove the clips and rivets
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Xbimmer
Posted on Friday, September 12, 2014 - 09:41 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Two years later and HD still supplies bad units. Pics of mine here: http://www.badweatherbikers.com/buell/messages/142 838/748598.html?1410528551

Thanks for the heads up, Al.
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