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Discussion Starter #1
My left side engine cover cracked so I have to remove the cover and the stator.

I'm having trouble locating where the stator wire is connected so I can remove the stator and cover in one. Thank you
 

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Year?

The wires should be very easy to locate. It's the only thing going into the stator. i can't imagine how you can't find them.

The stators magnetic and can be a little challenge to pull it out and especially get it back in flush. Sometimes an extra set of hands helps out.
 

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Discussion Starter #3
Sorry I meant left side alternator cover. The bike is zx6r 2011.

I can't seem to work out where the stator wire leads up too? Where is the end? I need to find the end to disconnect the wire so I can completely remove the stator and altanator cover completely away from the bike.
 

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Sorry I meant left side alternator cover. The bike is zx6r 2011.

I can't seem to work out where the stator wire leads up too? Where is the end? I need to find the end to disconnect the wire so I can completely remove the stator and altanator cover completely away from the bike.
Ohhhh ok. The stator plugs into the Regulator/rectifier. Which should be above the stator behind the fairing. You probably would have to take the fairing off, or at least pull it away from the bike to unplug it.

I'm actually not sure if it's a direct plug in, or if the stator plugs into a bigger harness that plugs into the regulator rectifier.

If you are just replacing th stator cover, you should be able to leave it plugged in and you should be able to get enough slack to pull the cover off and then unscrew then take out the stator coil. thats what I did on my triumph when I replaced the stator cover.
 

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On the 2011, its a single harness that runs from the stator to the r/r and plugs right in. The r/r on a 2011 is above the right front turn signal mounted to the inside of the fairing. If I remember correctly its the grey plug at the r/r.-Steven
 

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I'm actually going through the same process. What are you all using to get the bolts off on the inside of the cover? It's on ridiculously tight and I can't seem to get them off so I can take the stator off without stripping the bolts.
 

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I'm actually going through the same process. What are you all using to get the bolts off on the inside of the cover? It's on ridiculously tight and I can't seem to get them off so I can take the stator off without stripping the bolts.
Maybe get a socket with that hex head and use a socket wrench or even a breaker bar to remove. I got a socket set with all different size hex heads and it was a great investment. I have yet to be beat by a stubborn hex since.

If your stator cover is being replaced, and the current one is garbage, then put it in a vice to hold it still.

If you're really worried and got the stator and stator cover off of the bike, take just the parts down to the dealer or mechanic have them do it. My dealer is cool, they would take care of it for free, but I couldn't see a mechanic charging you more than $5 for 2 minutes of work. That $5 is nothing compared to the headache if you strip that bolt.
 

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if you are going to just replace the cover and reuse the current stator, why do you even need to locate the plug? Leave it plugged in, and just attach it to the new cover when you are ready to reassemble.

As far as the later question about backing out the star bit bolts, they are a pain in the ass. Last time I did this job I used hardened bits and an impact gun which worked a charm. When I reassembled, I used shallow head grade 10 hex head bolts which will make the job easier next time. Make sure to use a little thread lock!
 

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Yeah I'm using wrench on it now that fits perfectly, it's just too damn tight! I'll find a way to get it. I didn't even take out the wires because I literally just want to swap covers then put it back on.
 

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Yeah I'm using wrench on it now that fits perfectly, it's just too damn tight! I'll find a way to get it. I didn't even take out the wires because I literally just want to swap covers then put it back on.
Spray it down with some WD-40 or maybe hit it with a blowtorch. Maybe there's some stubborn locktite in there.

Use a second set of hands to hold the stator cover. I gotta imagine its tough to hold the stator and try to remove that bolt yourself.
 

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Spray it down with some WD-40 or maybe hit it with a blowtorch. Maybe there's some stubborn locktite in there.

Use a second set of hands to hold the stator cover. I gotta imagine its tough to hold the stator and try to remove that bolt yourself.
Yeah good point. I'll probably try again within the next week when it warms up again and the new gasket comes in.
 

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Spray it down with some WD-40 or maybe hit it with a blowtorch. Maybe there's some stubborn locktite in there.
I do NOT recommend this as there are plastic components on the stator and wire sealant that can easily be damaged by the heat of a torch.

Yeah I'm using wrench on it now that fits perfectly, it's just too damn tight!
I'm sure you are using the correct star bit, but as I stated above, its difficult to get a good hold of it and create enough torque with a normal hand ratchet to break the bolts loose. This is why I used an impact gun.

I didn't even take out the wires because I literally just want to swap covers then put it back on.
Exactly what I said to do, no? :devious
 

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That's what happened when I changed the stator cover on my 06. I couldn't undo the torx bolts while the stator was still connected.
I also used an impact drill and they came out easily
 
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