Finally getting back to this thread. Work gets in the way.. and my experience on this fix was a lot worse than Steve's!!!!
Here is a picture of the old and new stator with wiring harness.
NOTE: The harness looks goofy. Too much wire on the stator side of the oil seal. You have to trim the insulation on the stator side, then slide the oil seal towards the stator until the wires are the right length.
Then.. I noticed an extra, and OPEN hole in the oil seal. HUH??
Plugged it with a piece of plastic.
Put it together, and the oil seal is just a bit too tall.. it sticks up higher than flush with the cover.
OK.. sand it down a bit, but leave a bit of a bump so it will squish down to the gasket when I bolt it up.
Bolt it up.. oil leak. Open it up, and the gasket wasn't sitting quite right, and it got ruined.
Order OEM gasket instead of 3rd party knock off. New gasket in. Better material, smoother cuts, much nicer.
Bolt it up. Not leaking. Go for a ride... and .. it is trying to imitate a Harley by marking it's spot when I go to eat lunch. Another oil leak.
Open it up. There is oil inside the cable. That oil seal that gave me so much grief just isn't gripping the wires tight enough.. I though it slid kind of easy when I was adjusting the wires.
Now.. not a happy camper.
Grabbed the old oil seal. Took FOREVER to dig all old wires out of there.. but finally got all the pieces out.
Had to cut my nice new harness to take off the new oil seal and put the wires into the original oil seal.
Had to use a hair dryer to heat the seal up to get it soft enough so I could force the wires through.
Then spliced the wires back together. Same way Steve H did it. Staggered the cuts, buttsplice solder, heat shrink, very pretty end result.
Put it all back together.. again. (Man, I am getting GOOD at this!
).
Took it out for a ride this morning, and .. it looks like I finally got it back to how it should be. I'll keep an eye on the voltage output (my splices could have been better) and oil situation.
I'm still glad I replaced the harness, as the old one was pretty brittle.
HOWEVER, for those of you with not so high mileage, go Steve H's route and just get a stator that you will have to splice in.
Save some money, and may save you some of the grief I had!!!