I've heard only good about Ricky Stators, and He is really good about standing behind his products.  In fact I can see he's reading this thread right now .

Edited by toadl, 08 March 2012 - 02:59 PM.

I ordered the stator from him yesterday, and it should be here tomorrow.

im having the SAME issue, once you install your stator please let me know if the issue is resolved:)

I'm done with the install, and everything works great. All the tests pass, and I get 14.60v at idle! Except now I'm concerned about a ticking noise coming from the stator side of the engine that I think wasn't there before. Here's a photo of the newly installed stator, and I did do the loctite fix. See anything wrong? Should I take a video of the sound? Or am I being paranoid? http://i.imgur.com/DPEey.jpg

2 thrust washers on the torque limiter clutch shaft? And 2 thrust washers on the reduction idler shaft? (A thrust washer on each side of the locating snap ring)  Lost thrust washers can get snagged by the magnets and make noises.

If you're talking about these two, then yes I think so. http://i122.photobuc...cket/image0.jpg

Gear #1 according to that pic is supposed to come off, right? I was able to take mine off without taking any washers off first.

Yes. And yes it is correct that gear #1 can be removed without disturbing any thrust washers.  You see in the diagram, the thrust washer is relocated to the arrow location.

Ok here's a video of the sound:

You might have to turn your volume up.

My friend says it sounds like valves, but again, I don't think the sound was there before. Or maybe I'm being paranoid. You decide.

Edit: I just took it for a test ride and am now 85% sure the sound wasn't there before. Could I have messed something up by rotating any of the exposed gears?

Edited by Boris4ka, 11 March 2012 - 06:36 PM.

none of the gears on the stator side of the bike need to synch in any special position.


Are you sure the trigger coil was routed properly?  It is the one on the outside of the flywheel and others have had the wire rub if it wasn't under the guard properly.   Same might go for the other wires on their way out of the case.

Pretty sure I routed everything properly, here's a pic from a few posts up: http://i.imgur.com/DPEey.jpg

Have you watched the video above? Can you tell me if I even need to worry about that noise?

It is kind of a friendly noise but if it were me, I would like to find out what it is . I really don't know.

you said you did 'the locktite fix'.   I presume you mean on the stator.  Did you do 'the locktite fixES' including the primary nut and balance shaft?.    I do think it sounds like valvetrain.

If all you've done it change the stator then pull the new stator and look for signs of rubbing.

I seem to remember you had issues removing the engine casing so maybe something was unsettled when you did that?
Best way to know is to get back in there and see what's going on.

I just took it all apart again. Take a look at these photos: http://imgur.com/a/pvkYT (click on the photos to zoom in)

Yes, those are metal shaving stuck to the magnet. It seems like the tip of one of the magnets on the flywheel was hitting the metal clip that held the wires down. I must have bent that clip a millimeter. So looks like I found the problem, right? Do you think any metal shavings went in the oil? It seems the magnet pulled them all to itself, but it's weird that they were on the inside considering the part that hit was on the outside. Should I worry that any shavings could have gotten in the engine?

put a new battery in my bike and continued to run it, now my battery is junk wont hold over 6 volts... i need to figure out this issue its killing me.

supermoto_FREAK - you really need to start a new thread with a full explanation of the problem and what you have done to try to fix it.

Boris- Goes to show how close things are in there.  Very little metal was ground off.  Clean off what you find on the magnets, change the oil and filter, go ride.

I took the metal bracket off and found this damage on the case itself - http://i.imgur.com/3YIqu.jpg

My theory is the metal shavings from the bracket got pushed by the flywheel and did this damage. What do you think?

By the way, Noble you have been a great help throughout this thread (along with everyone else), thank you very much!

Edited by Boris4ka, 15 March 2012 - 10:00 PM.

I see a tinny little nick from the bracket. Nothing to worry about.

Noble, on 15 March 2012 - 09:52 PM, said:

The only thing I might do different is depending on how new the oil is I would just drain it and re-use it.

Pour the drained oil into a tall clear bottle to let it sit & settle out, then put most of the oil back in the bike, run the bike to confirm that the noise is no longer there and then take her for a spin to fully warm the oil up, then drain and repeat the above making sure to top up as the level will surely be lower now.

I would check the magnet on the sump plug after the first drain, I would also check the the frame oil screen for any bits caugh. I would also check the oil filter but again I wouldn't strictly replace the oil filter unless it was about due.
That's just my take as I'm not one for wasting oil & filters if there is life left in them. Large fragments can easily be removed from either and as there was only a small amount of metal removed I would expect there to masses of it in the engine.

But hey, it's your bike.

Seems to be working now, no more noise! I cleaned up the metal shavings and bent the bracket back. Thanks for the help!