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Replacing Stator Cover

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22K views 8 replies 6 participants last post by  banzai250  
#1 ·
Hey everyone, I'm looking to replace the stator cover, and I have a few questions:

1. With the bike on a rear stand, will any oil drip out when I take the cover off?
2. Last time I half attempted it, I realized there were so many different length bolts holding the cover on. Does anyone have a schematic which shows which goes where? I'm pretty sure I half guessed last time :eek:
3. The reason I didn't finish the job last time is someone mentioned I need silicone gasket material...any details on this?

Thanks guys!

As an aside, I changed my levers to some Hong Kong ones, and I set the cables based on the gap on the lever itself...I now realized that the stock and aftermarket metal pieces are probably different, so that gap specification is probably meaningless...what's a good way to tell if the clutch cable is adjusted properly?

No insurance yet, but it's 13 and sunny today, so I popped the battery back in, and fired it up just to put a grin on my face!
 
#2 ·
I know i'm not going to help at all. When I tried to change mine, I tried to get the stator off with allen keys (on the inside), and just about stripped them. I then read that you need some star shaped bit or something, not allen keys, even though it looks like allen keys. Just something to be aware of. I'm sure they have how to's online, or if not I would look for the kawasaki service manual. It's available online for free after digging around a little bit.

Now hopefully other people can actually answer your questions.
 
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#3 ·
I just did this a couple of days ago. This thread was quite helpful:
http://www.kawiforums.com/ninja-650r-er6/159310-generator-cover-bits.html

You didn't say where you live, pretty much every car/bike store will have something along the lines of 'liquid gasket' (basically just silicone sealant). You could probably get away without the sealant as the rubber grommet should form a decent seal, it doesn't hurt to play it safe though.

If the bike is level, you will lose about a litre of oil. It's probably worth just changing the oil and filter at the same time, unless you've only just done it recently.

When you take it off, watch out for the gears connecting the starter motor to the engine, they will probably stick to the cover. It shouldn't be too much of a problem if you've got the bike on a rear stand though.

As for the bolts, all I did was place them down in the order that they came out. I used the extra long bolt (goes in at about 5 o'clock) as my reference point.

When you go to put the cover back on, I would place a thick piece of plastic between the generator and the cover. This will stop it flying out of your hands as they come together (it happened to me, luckily no fingers in between). The piece of plastic should stop anything getting damaged and let you line them up easily.

These might come in useful
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#4 ·
I dont think all the oil will drip out since all of it ends up in the oil pan. So make sure you do it when the bike is cold.

Its really recommended to use a gasket. (You can buy gasket sheets at auto parts stores for cheap), then you can trace the cover on it and make the gasket your self.

Then I usually glue it with engine gasket maker on each side, (stator and engine, gasket in the middle).

You can buy engine gasket maker at any aouto parts store.

MAKE SURE you use the right torque setting on the screws. this parts are made of aluminum, you can brake them if you over torque it. (I think torque on these screws is aroun 25nm but im not sure)

A second choise is that you can just use gasket maker witho no gasket. Most of the time that holds fine.
 
#5 ·
Thanks guys!

I do have a gasket (I bought it when I bought the cover) but I was under the assumption you needed some extra silicone gasket material for something?

I have a torx screwdriver set so I should be good...are you referrring to the torque on the cover itself that I need to worry about, or the ones attaching the stator to the cover?

Edit: I changed my oil/filter right before winterization so I was really hoping to not lose too much oil.
 
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#6 ·
When I did mine I drained the oil first and did an oil change at the same time. It was still messy because of the oil that dripped out.

I bought a new Kawi gasket.

I did not put any silicone in the areas it said to. No leaks thus far.
 
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#7 ·
Well, did it today.

Couple things:

1) The stator was held on with allen head bolts, not sure about the whole torqx/star thing going on, but mine were definitely allen head (#5).
2) Finger nails are amazing for cleaning up old locktite
3) 2 people is MUCH MUCH MUCH easier to get the cover lined up and on properly with the damn magnet.

Thanks for the help guys. Insured the bike today, went for the first ride of the season. I'm all smiles now, and my bike looks great :)
 
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#8 ·
Mine were allen as well if I remember correctly. I had no problem getting them off. I had trouble lining up my cover but that just made it take a few minutes longer.
 
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