The "proper" way is to remove the inner primary cover - on some models there's not enough clearance to get the rotor out - the rotor gets hung up on the opening of the inner cover. The reason for the grinding is to gain clearance so you DON'T have to remove the inner primary cover to remove the rotor. Most people feel the amount of material that needs to be removed is not enough to weaken the casting, and it saves an hour of labor time.

 

Maybe it's just me, but the manual should contain the "proper" way to do it. According to him the manual states that you DO NOT have to remove the inner primary. With that in mind, the "proper" way to do it is with the inner primary in place.

 

For Christ's sake..............the 2007 Softail manual specifically states on 8-17 under Alternator of section 8 (electrical) under "Note" "It is not necessary to remove the inner primary chaincase to remove the alternator"

 

Yes, you are correct. I was just answering Skully's question of why there would be any grinding needed. And I stated "On some models.." On my '06 Dyna FXDBI, you either have to grind for clearance, or take off the primary chaincase to get the rotor/comp assembly off.

 

There was another thread that makes it look easy. The thread is about replacing compensator but you will get down to the point where you can drop a new stator in. The grinding is so you can slide the rotor off the shaft to get to the stator without having to pull the inside primary cover off the shafts.

https://www.hdforums.com/forum/touri...it-w-pics.html

 

Guess I messed up when I changed my stator. Left the inner primary on...

Gotta love it when folks give advice on stuff they haven't done themselves.

"Oh yea, my ex brother-in-laws, second cousins, parole officer said it was so!!!"

Beav

 

Check the magnets on the rotor too. Sometimes the heat causes the glue to weaken, so if you try to wiggle them they can pull off. I've seen this happen helping friends out. We use JB Weld to glue em back on, but you have to clamp them over night. Or just replace the F'n rotor with the stator.

Hey, Beav, you got a 99 I think. Plenty of room on that primary setup. My 05 is good too. I think it was 06 or 07 when the clearance issues started?

 

Yea but, you took your jugs off....I don't think he'll have to do that. LOL

 

Inner Primary case needs to be ground when installing the SE COMPENSATOR and not when replacing the stock rotor stator. Mine slipped right in and out no issue. 06 dyna

 

That thread is for the oversized SE Compensator only.