How to Replace a Road Glide Stator

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Modern Harley-Davidson motorcycles are a lot more reliable than vintage models. One problem that does seem to crop up occasionally, though, is stator failure. The symptoms are the engine misfires and stalls, after which the starter will not turn the engine over. If the battery accepts a charge and then the engine starts and runs, followed by a repeat of the initial problem, you may have a bad stator.

Things You'll Need

  • Socket wrench set
  • Combination wrench set
  • Allen wrench set
  • Drain pan
  • Harley-Davidson primary chain wedge
  • Service manual
  • Ratchet strap
  • Loosen the clutch cable adjustment as much as possible. Refer to the directions in the manual.

  • Remove the drain plug at the bottom of the primary case. Drain the oil into the drain pan.

  • Remove all of the bolts that hold the primary cover. Do not forget the four bolts in the center of the cover. Remove the cover. Be careful not to tear the gasket.

  • Put the transmission in fifth gear. Apply the rear brake and fasten it with the ratchet strap. Turn the jam nut on the clutch drum counterclockwise to loosen it with a 1-1/8-inch socket. Remove the lock-ring and adjuster plate.

  • Remove the two small bolts on the chain adjuster and allow it to swing out of the way.

  • Jam the plastic wedge between the chain and front compensator sprocket to prevent the sprocket from turning. Place a 1-1/2-inch socket on the nut in the center of the sprocket and turn clockwise with a breaker bar to remove it. Slide the sprocket and clutch drum off along with the primary chain.

  • Remove the bolt from the center of the starter jackshaft and pull the jackshaft off. Remove the bolts holding the inner primary case. Loosen the two screws that hold the starter to the primary case. Remove the primary case.

  • Pull the rotor off. Unplug the stator connector. Remove the screws that hold the stator and pull it off. Replace it with the new stator, and reassemble all parts in the reverse order of disassembly.

  • Refill the primary case with oil. Follow directions in the service manual to readjust the clutch cable.

References

  • "Harley-Davidson Service Manual: Touring Models"; Harley Davidson Motor Co.; 2009
  • Photo Credit Jupiterimages/Photos.com/Getty Images
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