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Replacing the stator

WhiskyGalore

WhiskyGalore

Joined Sep 2011
73 Posts | 0+
West Highlands
Hey folks. Have bought an Electrex Generator to try and sort out the charging woes on my Gen2. Was wondering if it's a job I can tackle easily myself and what other parts or special tools will I need for the job, if any? Cheers :thumbup
 
It's easy enough to swap the stator....
can be a bit fiddly getting the wiring through the v of the engine (tip1: tie a good piece of string to the brown connector, do this before you start to strip down, then you can use the same string to pull the new connector back through the engine when you're putting it back together...saves loads of swearing and arsing around )
tip2: have a new gasket to hand....and don't forget to use loctite on the stator screws and security clip screw inside the stator cover
tip3: have some fresh oil abd a filter to hand
No special tools required.
Do not overtighten the stator cover screws.
Look out for a thin black wire (goes to the neutral switch iirc) when you are putting it back together, it's easily pinched between the cases.

tip4: have a few tinnies to hand so that you can smugly sit back & admire your handywork
 
When removing the bolts that hold the stator cover, make sure you have ALL of them off before you start pulling on the cover.
There is a fair amount of magnetic force pulling on the cover so be prepared for that when removing and especially replacing the cover.
 
Nothing to add except I chopped the brown connector and hard wired but that's your call,and I fitted a 12ah battery to give the stator more to do as well
 
Also, if you have time, go buy 3 long 6mm? bolts.
Cut the heads off, and dress the sawn ends up.
Then when you come to put the stator cover back on, screw these loosly finger tight into the engine casing one at the bottom, one to the right, and the last one on the left.
You can then slip your gasket over these, and then offer the stator cover over them also.
It really makes things easy to line up, and prevents that magnetic pull from misalighning things.

Oh yeah, watch your fingers when you put it back on, the magnet is so strong, it can snap back into place and pinch your fingers. Hurts like **** :lol
 
Last edited:
+1 on hurts like ****.

I used a little bit of rtv silicone to keep the gasket in place on the engine side too.
 
Thanks guys….much appreciated, one last question (for now at least :) ) what online parts supplier do you guys recommend for bits, namely gaskets, filters, consumables and such for your Tuonos?
Cheers men :)
 
OK job done, new stator in and ready for reassembly once I source a gasket and get a new oil filter (see my other threads)

Old one looked pretty well cooked so am happy with my afternoons fiddling, very enjoyable :)

Heres the old stator…

ResizedResizedIMG_0601.jpg


ResizedResizedIMG_0602.jpg
 
Great bits of information shared here - thanks.

One question... does the gasket need any gasket sealant, or does it go on dry?

Thanks again.
 
Dry...

If you havnt bought a gasket already... genuine ape ones are a ripoff... pattern ones are about a third of the cost.

:yes
 
Hi WhiskyGalore

I'm in the same boat, my stator packed up on my 2007 Tuono and was wondering which Electrex generator did you purchase?, I've emailed "Electrex World" regarding a replacement stator and have no reply.

Thanks in advance.:thumbup
 

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