So . . . almost a year ago (and a broken collar bone ago) I pulled the engine and tore into it to fix leaking gaskets and other little things. I also followed everyone's good advice and picked-up a new stator (on account of the original looking a bit toasted). So over this past weekend I started putting the engine back together. I put the new stator in (Electrosport ESG-050) and bolted the cover to the crankcase (without gasket and just a few bolts snugish). I gave the engine a few turns and then pulled the cover off to make sure everything cleared okay . . . it didn't. Here are the pics I took showing the orginal and Electrosport stators, labelling some questionable difference.
This is with the outboard side up. The original has the cross-pole wires on this side, but the Electrosport doesn't, yet they both have the tap on this side.
Now on the other side, the flywheel side . . . the problem
side . . .
Since the Electrosport has the cross-pole wires on this side, the clearance the original stator had just isn't there. Some of the rivets in the flywheel rubbed on the windings enough to bare the wire.
Now during my work I pulled the flywheel. When I reinstalled it, I wiped-down the crankshaft taper and the hole in the flywheel. I also wiped some fresh motor oil on them. I torqued the flywheel bolt to 75ft lbs and then to 95ft lbs. The teeth on the flywheel lined-up perfectly with the teeth on the counter-balancer (neither too far inboard or outboard). I really doubt the thickness of the cover gasket could have caused this.
So have any of you heard tell of (or laid eyes on) such a thing? To me it looks like Electrosport just put this stator together wrong, but their images on their web site look just like what I got from them.
Any help any of you could offer would be great.