Tuxedo Mod with GC-Extreme Plate and M6 50mm 12,9 grade bolts
About 2 weeks ago after my swimming session at YMCA I was getting ready to go home. I went to my bike and tried to start it but battery didn't have enough juice to crank the engine and after a couple more times it eventually drained the battery completely
. Luckily I was only 5 miles away from home. I called my wife she picked me up then we drove back to the bike with a car battery. I tied the battery to the back of the bike, road home with it
.
In short my stator gave in at 26,000 miles. I called a couple motorcycle repair shops to get some estimates. The average cost of replacing the stator was about $800. I had already watched several videos about Tuxedo mod and read almost all the the threads about it.
Finally, I decided to go with the mod and ordered my ElectroSport stator and the stator plate from http://www.ElectroSport.com/shop/index.php?route=product/product&product_id=63&search=stator"]http://www.ElectroSport.com/shop/index.php?route=product/product&product_id=63&search=stator
GC-Extreme's plates are excellent. It is micron level precise. It fit with no hassle. Great, clean product. Glenn (from GC-Extreme) answered all my questions regarding the plates ptiently. I got my shipment within few days. Plates came with two M6 x 1mm x 25mm (12,9 grade) and 2 M6 x 1mm x 15mm (10,9 grade) machine bolts.
I installed everything ran the wires from the original holes and closed the side cover.
However, the idea of splitting the 40mm thread hole into about 10mm on the plate side (5mm part of the thread is unused because the spacer's ribs) and 25mm on the stator side of the cast aluminum spacer kept bothering me. Even though I used a ton of loctite blue on the threads I couldn't trust a cast aluminum spacer with only 10mm treading on plate side.
So I decided to use 50mm 12,9 grade machine bolts.
I removed the cover and the stator and re-assembled by keeping the bolt heads on the stator side and the nuts on the plate side. I shaved the spacer and added 3 washer between the plate and the spacer for each bolt. After tightening the nuts I cut the about 4mm excess from the bolts. Please see the pictures attached.
Sorry I took my pictures after finishing the whole job. I used my old stator and the extra bolts and nuts for the dem0 purposes.
Now, I get about 14.5 volts at idle. This goes down to 13.9 when I rev it up to 3,000 rpm.
So far no complaints on the ElectroSport stator.
GC-Extreme's plate fir perfectly. I completed the whole process under 5 hours.