Join Date: Oct 2007
Location: SoCal (SF Valley) 91343
What takes the time is all of the prep work. If you already did an ear shave then that will save some time dealing with the air box. The problem is that the frame is poorly designed with regard to being able to access the main stator cover. The bottom bolts are tucked nicely beneath the frame rail, thus preventing you from removing them unless you move the engine around. I spent anywhere form 30 - 90 minutes a night over the course of 3 or 4 nights doing the "prep" work of removing everything. Once I had all the parts cleared and the engine dropped it was actually pretty smooth. The actual stator replacement time was less than 1 hour, which included pulling the cover, removing the old stator, cleaning the hell out of the cover and removing the old gasket, swapping out the oil seal, bolting up the new stator, and getting it back on. Saturday morning I started at 8 putting the bike back together (stator already on and engine back in the frame). She was fired up by 10:15 and on the road by 10:45.
As far as oil goes, it loves to hide in little places, and even though I originally drained it overnight, there was still some seepage whenever I would shift the engine around. Same with coolant. Not a lot, but enough that you should keep plenty of paper on the floor to catch it. The only other tips I can offer are to definintely NOT reinstall the bevel gear case until the engine is remounted, and use some RTV to hold the new bevel gasket on the engine side instead of on the bevel gear itself. I had to pull that damn thing off probably 4 times to get it just right.
After reading the above post, I wish I had access to the tools to do the cut and re-weld. That sounds like the ticket.....