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Im an idiot, NEED help

I'm not sure if this is the proper place to post this. I should start off by saying I'm by no means great mechanically. On a scale of 1 to 10, 1 being not able to check your oil and 3 being able to change your tire on a car I'm maybe a 4. I had an issue on some gravel in a corner and laid my bike down on the left hand side, damage was to the bar end, stator cover and a bolt on the rear of the bike holding the chain guard. All and all I was actually pretty lucky considering.

I decided hell with it I'm going to attempt this myself (with the help of a friend). Ordered a new Cover, gasket and bar end. The bar end any idiot can do took an allan key and 1 minute. For the stator cover I couldn't find any how to's on the interweb for this particular bike I did see a video on a different bike I figured how different could it be? Please keep in mind again that I'm not a mechanic, I'm not even good at mechanical things but I figure I'd post this because it might help someone else out. My description of parts or tools may not be be 100% accurate but I'll do the best I can.

I was going to drain the oil but then we were thinking it might not be necessary, I could see a good argument for draining it however we did not. We started by loosening all the necessary bolts and the oil started seeping from the bottom as expected. We're looking at the hose from the rad knowing once we loosened it coolant was going to come out. We obviously didn't want coolant in the engine so a light went on and maybe we should have started there. For anyone attempting this please start here, drain the coolant before even touching the bolts holding the cover on. Probably obvious to all of you but a dummy like me not so much. We loosened the hose clamp, pulled the hose and drained the coolant disaster averted.

So I cut some cardboard out and wrote down numbers (thank you random youtube guy) so we could be sure all the bolts went back where they came from. We started removing the bolts one at a time and sticking them in there place. Once they were all removed it was time to cross our fingers, remove cover and hope everything worked out as planned. It took a little bit of wiggling but we got it off slowly we didn't want to disturb anything and be sure we could get it back together. The wire with the rubber stopper easily pulled out and then there was 2 bolts holding it down and 3 more bolts holding the stator. This is kind of a two person job, I had a thought as I'm typing this maybe the wire can be unplugged allowing you to remove everything in one step but I'm not that smart. Once we have the two bolts holding the wire and the 3 bolts holding the stator it came right out and the cover came free. I rested the stator on some random piece of plastic I found in my garage and it was time to transfer the parts to the new cover. We also had to remove the cover that connects to the Stator Cover that the hose goes into, it is its own assembly.

The large white plastic gear you see there has a cotter pin holding it down. The large bolt on the front of the Crank Case needs a 14mm allan key, I didn't have one that big. Down to the local auto store Cover in hand we went, ended up finding an allan key that would work and grabbed a pair of pliers for that cotter pin. I'm sure most of you will have all of this stuff, I have a rag tag assortment of tools mostly things I pick up as I need but not being that mechanically inept it's not that often I do my own work on anything. Got what we needed, also grabbed some oil because I knew I'd need to top it up. We're back in my garage removed the cotter pin and the white plastic gear came out. The allan key removed the large brown bolt no problem. We started transferring everything into the new case, there are some dowels as well as a metal sleeve that goes in one of the holes make sure you get everything moved and match it up.

Alright almost done hard parts done so we figure. I clean the connection point for the new gasket on the bike because the bike is so new there really isn't any old gasket stuck to it it came off in one piece. We bolt the housing piece where the radiator hose goes into on first. I hold the cover he bolts the stator and the piece holding the wire back into the new case and we put the new gasket on. Up to this point everything actually went pretty smooth but getting it back on was a bitch. Maybe it's because I'm not a mechanic and the bike knows this, it's decided to get a rise out of me. It also could be because the large round cylinder inside of the engine is magnetic and is sucking the cover in everytime I try and line it up. This took some patience, I'm sure most of you here could do this first try with Jedi mind tricks and skill but like I said I'm an idiot. The gasket kept falling off nothing was lining up I was swearing.....a lot then all the sudden it was like the skies parted and it was in. I did a visual inspection it looked good, gasket looked good from what I could see all around. So we began putting in the bolts in a crossing pattern hand tight (thanks youtube) until they were all in. Started tightening them like you would when putting on a tire to try and make sure the pressure was applied evenly all around the gasket for a good seal. Made sure everything was tight but not to tight I didn't want anything to strip. Attached the coolant hose and everything was back together.

Topped up the oil, it had leaked about 24 ounces, topped up the coolant and started her up. Now I haven't taken it for a ride but I did let it run for 10 minutes in the garage and everything seems to be holding fine no leaks or anything. Please read the imaginary disclaimer about me not being mechanically inclined and this is just for shits and giggles. If you want to try this yourself take your time and get someone to give you a hand because four hands are better then two. I don't really have any photo's of putting it back together but use your imagination, it was opposite of it coming apart. The Frame Sliders look untouched because they arrived 2 days after I laid it down and went on after.

Photos
Stator Cover - Imgur
I was in the same predicament you have stated above and need help ASAP! Let me explain and digress my frustration. My stator/alternator cover was lightly damaged after a dumb laydown of the fz09. So i decided to purchase a stator cover, watch videos and try myself. So i take off the four bolts, look down for a second and feel oil dripping on my leg from the fourth and bottom most bolt I took off. I put the bolts back in asap and the bike is sitting till further advice, what should I do? The engine oil level seems to be full as i checked through the sight glass, BUT. Is the bolt that oil came out of okay if not dripping? IF not what do I do? Lastly, how the f**k do I replace the stator cover without leaking oil on my leg?? I'm confused on what to do, how to fix the issue and how to get the aftermarket cover on the bike. Any help would be great! Thanks in advance.
 

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I also have the oil leaking problem. Installed the GB racing covers, and the left side crank case cover refused to stop leaking oil out the bottom of the 4 bolts,even with stock copper washer in place. Anyone successfully find a reliable fix?
 

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I'm not sure if this is the proper place to post this. I should start off by saying I'm by no means great mechanically. On a scale of 1 to 10, 1 being not able to check your oil and 3 being able to change your tire on a car I'm maybe a 4. I had an issue on some gravel in a corner and laid my bike down on the left hand side, damage was to the bar end, stator cover and a bolt on the rear of the bike holding the chain guard. All and all I was actually pretty lucky considering.

I decided hell with it I'm going to attempt this myself (with the help of a friend). Ordered a new Cover, gasket and bar end. The bar end any idiot can do took an allan key and 1 minute. For the stator cover I couldn't find any how to's on the interweb for this particular bike I did see a video on a different bike I figured how different could it be? Please keep in mind again that I'm not a mechanic, I'm not even good at mechanical things but I figure I'd post this because it might help someone else out. My description of parts or tools may not be be 100% accurate but I'll do the best I can.

I was going to drain the oil but then we were thinking it might not be necessary, I could see a good argument for draining it however we did not. We started by loosening all the necessary bolts and the oil started seeping from the bottom as expected. We're looking at the hose from the rad knowing once we loosened it coolant was going to come out. We obviously didn't want coolant in the engine so a light went on and maybe we should have started there. For anyone attempting this please start here, drain the coolant before even touching the bolts holding the cover on. Probably obvious to all of you but a dummy like me not so much. We loosened the hose clamp, pulled the hose and drained the coolant disaster averted.

So I cut some cardboard out and wrote down numbers (thank you random youtube guy) so we could be sure all the bolts went back where they came from. We started removing the bolts one at a time and sticking them in there place. Once they were all removed it was time to cross our fingers, remove cover and hope everything worked out as planned. It took a little bit of wiggling but we got it off slowly we didn't want to disturb anything and be sure we could get it back together. The wire with the rubber stopper easily pulled out and then there was 2 bolts holding it down and 3 more bolts holding the stator. This is kind of a two person job, I had a thought as I'm typing this maybe the wire can be unplugged allowing you to remove everything in one step but I'm not that smart. Once we have the two bolts holding the wire and the 3 bolts holding the stator it came right out and the cover came free. I rested the stator on some random piece of plastic I found in my garage and it was time to transfer the parts to the new cover. We also had to remove the cover that connects to the Stator Cover that the hose goes into, it is its own assembly.

The large white plastic gear you see there has a cotter pin holding it down. The large bolt on the front of the Crank Case needs a 14mm allan key, I didn't have one that big. Down to the local auto store Cover in hand we went, ended up finding an allan key that would work and grabbed a pair of pliers for that cotter pin. I'm sure most of you will have all of this stuff, I have a rag tag assortment of tools mostly things I pick up as I need but not being that mechanically inept it's not that often I do my own work on anything. Got what we needed, also grabbed some oil because I knew I'd need to top it up. We're back in my garage removed the cotter pin and the white plastic gear came out. The allan key removed the large brown bolt no problem. We started transferring everything into the new case, there are some dowels as well as a metal sleeve that goes in one of the holes make sure you get everything moved and match it up.

Alright almost done hard parts done so we figure. I clean the connection point for the new gasket on the bike because the bike is so new there really isn't any old gasket stuck to it it came off in one piece. We bolt the housing piece where the radiator hose goes into on first. I hold the cover he bolts the stator and the piece holding the wire back into the new case and we put the new gasket on. Up to this point everything actually went pretty smooth but getting it back on was a bitch. Maybe it's because I'm not a mechanic and the bike knows this, it's decided to get a rise out of me. It also could be because the large round cylinder inside of the engine is magnetic and is sucking the cover in everytime I try and line it up. This took some patience, I'm sure most of you here could do this first try with Jedi mind tricks and skill but like I said I'm an idiot. The gasket kept falling off nothing was lining up I was swearing.....a lot then all the sudden it was like the skies parted and it was in. I did a visual inspection it looked good, gasket looked good from what I could see all around. So we began putting in the bolts in a crossing pattern hand tight (thanks youtube) until they were all in. Started tightening them like you would when putting on a tire to try and make sure the pressure was applied evenly all around the gasket for a good seal. Made sure everything was tight but not to tight I didn't want anything to strip. Attached the coolant hose and everything was back together.

Topped up the oil, it had leaked about 24 ounces, topped up the coolant and started her up. Now I haven't taken it for a ride but I did let it run for 10 minutes in the garage and everything seems to be holding fine no leaks or anything. Please read the imaginary disclaimer about me not being mechanically inclined and this is just for shits and giggles. If you want to try this yourself take your time and get someone to give you a hand because four hands are better then two. I don't really have any photo's of putting it back together but use your imagination, it was opposite of it coming apart. The Frame Sliders look untouched because they arrived 2 days after I laid it down and went on after.

Photos
Stator Cover - Imgur
So its been a few years. How has the replacement cover held up? Any leaks, issues? I am about to replace mine.
 

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I'm tired of the oil leak with the GB racing cover after a low speed crash rashed out my OEM sidecase, I'm going to buy a new yamaha left side engine cover/stater cover and gasket plus Allen headed screws from stealership and install it myself. GB racing cover isn't worth a shit. The engine leaks oil all the time and it was $80 USD wasted. I should of known better than buy a British made motorcycle part that was required to be oil tight...

I'll post if anything not covered by njvt13's helpful DIY might be good to know for other members here. Going to change mine out as soon as parts arrive. I think the screw template was a great idea and will be using that since I have no idea if I'll be confronting a whole bunch of different screw lengths when I pull my side case off.
 

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I know it's been a while since this post, but thank you for the tutorial. Swapped out covers this weekend. Your instructions made it feel a lot less daunting. Thank you.
 

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Very helpful post thanks for posting this!

Unfortunately I went down on my xsr and stator cover is very scratched. I just wanted to double check to see of part #7 and 8 in the diagram is necessary to buy also or can the old be reused.

Thank you
 

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I know this is most likely an outdated thread but I in the same situation as the poster of this thread. Almost the same mechanical abilities and was just wondering how the white gear piece was removed. Also is it bad to reuse the coolant/ oil if its still in good condition?
 

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Awesome post! I’m about to replace mine on the new FZ09 I just purchased. Gasket and case were about $85 shipped from revzilla. This is what I’m dealing with
156602
 

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So I’m doing this right now and have everything off but the only thing I have holding me up is the wire at the top of the case. I don’t want to damage it , how do I remove it safely?
 
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