Alternator/Stator cover Replacement

[Nemo]

When I bought my '04 919 in November (my second, after the first was totalled by an inattentive driver in October), it had some scratching on the alternator/stator cover from a drop by the previous owner.

Forum member Tom very generously donated his old cover after installing the Circuit One cover on his own 919. Thanks Tom!

I ordered the proper gasket from Service Honda; it wasn't very expensive, and apparently the clearance it provides is necessary as well. Don't just use RTV to seal the new cover.

I timed the alternator cover replacement to sync up with my oil change. I drained the oil, replaced the filter and then removed the 9 bolts holding the cover on. The stator is magnetic, and wants to stick to the flywheel, of course. So it took some tapping with my rawhide mallet to release the cover. There wasn't much oil loss, since I'd already drained the oil, but I kept a pan underneath to catch the drips nonetheless.

After removing the cover


Old cover containing stator


I elected not to unplug the 3p connector which would release the stator wire, so I had to keep the whole arrangement balanced on my knees.

I scraped off the old gasket material, then applied a very light coat of RTV to several spots on the mating surface, and attached and aligned the new gasket. I removed and cleaned the 2 dowel pins, long and short, and unbolted the wire clamp and the 4 allen bolts holding in the stator, then bolted everything back into the new cover and replaced the dowel pins.

With new gasket


Closeup of reduction gear--long dowel pin on the cover slides in here to become the reduction gear shaft.


Closeup of wire grommet seated in new cover (I used a bit of RTV to seal it in)


Realigning the new cover, the bolt holes, and slotting the dowel pins into their holes was challenging.


The magnet wanted to pull the cover and stator on, but seemed to want it to be misaligned. It took some frustrating fiddling and moving the reduction gear onto the long dowel pin before I was able to align everything--but at last, victory was mine. I made sure the wire grommet was in its proper place, then torqued down the cover bolts.

All buttoned back up, no scratches!


I then added the oil, and was ready to ride.

[ilovheros]

Nemo, I was afraid to do this untill I read your great info, thanks

[Ken]

Great pics. Nice post, Nemo!

[SV650s]

Nemo: Thanks for the informative How-To. This thread will be added to the 919 Helpful Topics.

[adamjayp]

Spectacular write up - and with pics too!

[cpg74]

Nice write up

After seeing this and a few others of yours, you should write/publish repair manuals or instruction guides for whatever needs instructions.

[Tom]

Nice job and nice write-up!

What's next? The racks and luggage?

(P.S. : If I had thought that cover looked as good on my bike as it now does on yours, I never would have sent it to you.)

[marylandmike]

Excellent. Thanks Nemo!

[Nemo]

Originally Posted by Tom

Nice job and nice write-up!

What's next? The racks and luggage?

(P.S. : If I had thought that cover looked as good on my bike as it now does on yours, I never would have sent it to you.)

Thanks Tom! I think I lost some street cred when I took off the old scratched cover, but I like the sleek look.

Funny thing is, I am a mechanical noob; didn't know how to so much as change my oil 3 years ago. It's been fun to learn (barring a stripped oil pan on a previous bike...arrgh) and document the process. I'm grateful to the folks online, here and on other forums, who have so much of their own expertise to share.

I added new Givi crashbars, but by the time I was working on that, it was dark and I was going by headlamp--photographing that install wouldn't have worked so well.

Once I can find some Givi E360s or E41s used, and perhaps a topbox as well, I think I'll spring for the Givi or SW-Motech racks and document that install, too.

[powsmitty]

Once I can find some Givi E360s or E41s used, and perhaps a topbox as well, I think I'll spring for the Givi or SW-Motech racks and document that install, too.

Have thought of JC Whitney for luggage? I ordered their top box and the Givi rack with the Monolock base plate. Got the case within a week and still waiting on the rack. Should be at my house on Wed. The JC Whitney top case ain't that bad of a deal, got mine for $62.00 shipped, and I have heard that some people use them for side cases as well. It's the large box by the way.

http://www.jcwhitney.com/autoparts/S...&sku=zxe20997G


-smitty

[Nemo]

Originally Posted by powsmitty

Have thought of JC Whitney for luggage? I ordered their top box and the Givi rack with the Monolock base plate. Got the case within a week and still waiting on the rack. Should be at my house on Wed. The JC Whitney top case ain't that bad of a deal, got mine for $62.00 shipped, and I have heard that some people use them for side cases as well. It's the large box by the way.

http://www.jcwhitney.com/autoparts/S...&sku=zxe20997G


-smitty

Let us know how the quality seems when they arrive! I'm more inclined toward something with pretty rugged build quality. If I had more access to tools and fabrication know-how, I'd be inclined to fabricate a mounting kit for a pair of modified Pelican cases, and use those for luggage!

[powsmitty]

Will do.


-smitty

[Brewcrew02]

Bump... Finally got to utilize this write up how to.... Took all of 30 min to replace my shattered cover after the digger. Thanks you SO much for the great info. It's so easy when you actually get down to doing it!

[MF1VE]

Thanks for bumping this - I love how-to posts, and this one is really good!

[Brewcrew02]

MF1VE--- Like the center stand?