So I don't destroy my stator...

I got everything cleaned up for the stator. The rotor was testing at almost 6 ohms and is now at 4.6-4.8 which is in good range. Just had to clean everything up. Replaced the brushes. Remember I couldn't find the wear lines? Well.. that's because they were gone. One brush was done and the other had the wear line right at the tip. The new ones are obvious where the line is.

So I went to put the stator back in it's place but it is such a tight fit. What is the best way to replace the stator without damaging anything?

 

Update... I did try to fit it a little bit ago and it really doesn't want to slide in there. There has got to be a trick to getting it in without messing anything up. If I force it I am affraid I might ruin the stator

 

I thought I would for sure have an answer by now... from Fitz for sure. Haha. Fitz, you are practically doing all of the work on my bike from afar. Haha

 

I had an instructor back in the day, who when asked "how the hell do we get that back in there?" answered:

"Manual dexterity, son, manual dexterity."

This is where that "lining up the bolts with the grooves" thing comes into play, PLUS you need to get the wires happily routed back into their little grommet and tucked where they have been living before you came along, PLUS get the new (aluminum) gasket trapped where it needs to be in the process, PLUS get the cover lined up so it can go straight on.

It would help if you had three hands, but instead:

Takes patience, good lighting, and manual dexterity. A little gentle wiggling accompanied by the correct amount of swearing helps. You can "test fit" a couple of the bolts and use them as a guide.

Hold off on the beer until afterward.

 

Haha Fitz. You are an asset to the motorcycle worls... seriously. I did get it back in there last night and it took a bit of patience. Maybe overshot on the swearing but now I know I have a decent alternator. Resistance is all where it should be, new brushes, new gasket. The gasket was trying to be naughty so I put some di-electric grease on there so the gasket would stick to the cover til I got it on. And now everything on that side is shiney and ready to run.
Now for the crank case/clutch cover. I need to start on the darn brakes but I want to get everything I need from xj4ever in one shot.

 

I thought Manuel Dexterity was the President of Mexico?

 

That's Manuel Labor.

 

Haahahaha hahaha... oh yeah... HAAAAAAHAHAAAAHAHA