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Join Date: Nov 2007
Location: Chandler, Arizona
I just got started on replacing my stator today. I'm doing mine what I consider to be the right way, by removing the engine. If you are going to do the Tuxedo mod, I still suggest removing the engine to do it. At least it will be easy to replace if it fails again. My feelings are that when you start cutting/grinding on the stator cover, you are going to get a lot of metal particles in the engine, and most of them are not going to come out. They will circulate through the lubrication system, getting into all kinds of bad places, and probably doing lots of damage. Other have done it, but I would never trust an engine that I know has metal particles in it. They can damage all the bearings, and even get stuck in the rings and scrape up the cylinder walls.
It's your bike, and if you want to do it that way, it's certainly up to you. But to me this is not a place to be in a hurry. I figure on it taking me at least 6 weeks to complete, working on it about an hour a day but not every day.
Not sure about the R/R (my stock one lasted 92,000 miles, and still seems to be good) but Tim is definitely the place to get the stator rebuilt, regardless of time. I have seen this come up on other forums as well. I'd avoid the cheap crap on eBay, or you'll likely be doing it again.
I am a motorcyclist, NOT a biker.
1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike