Stator rubber seal

[Snapey]

Let's presume your stator is stuffed & a new one is needed. Do you buy OEM at AU$587 or after market at AU$165. With the OEM stator you get the complete unit but with after market stator a vital piece is missing ... the rubber piece that the wires pass through. For that $400 saving you decide to make the rubber seal but getting the wires through the rubber is near impossible without a couple of special tools.

Firstly you need some rubber but one that is not affected by oil. I used 1/2" thick press tool die rubber but I'm sure a specialist rubber store would have something that is suitable.
A piece of 3.0 diameter wire sharpened to a point ... I used a scriber.
A piece of 3mm dia tube available from most hobby stores for about $7/meter
A vice helps & some oil

Cutting the rubber to size & shape you'll have to sort yourself but I used a bandsaw to cut, a linisher to clean up the cut and a 1/4" wide grinding wheel for the groove. A new angle grinder wheel would do there.

The rubber piece is finished but you need to get those wires through the three 2.25mm diameter holes you just drilled.
I mount the scriber in a vice then pass it through the rubber piece using some oil as lubrication.
I then mount the tube in the vice and the scriber then pushed against it. The rubber can then be pushed over the tube.
Push the stator wire inside the tube ... maybe 150mm.
You can now pull the rubber off the tube and the first of the three wires are through the rubber.
Repeat for the other two wires.

[Snapey]

continued

[Kiwifruit]

Nice handy tutorial Pete

[froudy]

Thanks Snapey...Very handy

[Hooli]

Or find a place that rewinds them on an exchange basis. They'll reuse the rubber block from the original stator.