TOPIC:

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I only found 5 or 6 like yours with the cross-hatch pattern on EB. one of them is nos & over-priced.  3 or 4 are in the $55T range.  
There's one from a 79 model that's $28T but it doesn't have the cross-hatch pattern.  None of them looked that great.

search terms I used:  KZ650 generator cover. also searched KZ650 with: alternator cover. stator cover. dynamo cover. engine cover. 

Yes, I've seen them all. Used ones don't look so great. There is NOS found by PN but without a pic. In $80 range which is the same as timesert M5 kit. Asked seller for pic might be solution.
 

That´s an unusual size for a stator screw/bolt!!!

wrote:

That´s an unusual size for a stator screw/bolt!!!

Indeed. Unusual to see hex bolt on motorcycle too. I guess it's because made in USA?
My bad for breaking it. Should have detected extreme force and try to heat it/etc.

But for now - only way I can fix it myself with what I have - is to drill 6mm using stator hole (it's probably 5.5 now on stator). or try 5mm bit and see how loose it is and tap it for M6

No eBay APP ID and/or Cert ID defined in Kunena configurationThe stator bolts should be a socket type allen screw. M5 x 30.
My 81 KZ650-CSR uses the same screws.


 

wrote:

wrote:

That´s an unusual size for a stator screw/bolt!!!

Indeed. Unusual to see hex bolt on motorcycle too. I guess it's because made in USA?
My bad for breaking it. Should have detected extreme force and try to heat it/etc.

But for now - only way I can fix it myself with what I have - is to drill 6mm using stator hole (it's probably 5.5 now on stator). or try 5mm bit and see how loose it is and tap it for M6

Try to bore 5 mm for M6 first with Loctide to fill the miss bore attemp, don´t over tiden the thread. The stator will hold in place with 2 bolts only . There is no friction or torque force, only centering abilitys are nesseary. If failt, try next step for M6 timesert repair insert...

wrote:

Try to bore 5 mm for M6 first with Loctide to fill the miss bore attemp, don´t over tiden the thread. If failt, try next step for M6 timesert repair insert...

Yes. That would be ideal. But 5mm bit will not center with stator body (I assume hole is at least 5.5). I have an idea though. Will see what happens. 

Read my edited text please....
The stator will be centered in position by the ring in the stator cover!!!
The screws lock only the rotation of the stator by the magnetic force of the rotor.

You might be able to work the piece out. A small punch against the side of the broken bolt and drift it counter clockwise. You could try a “vicks” bit to center I new hole.

Success! Stator hole is about 5.5mm, using it as a hole I drilled out old stuff. 5.5 little too big for M6 thread, but it's OK, no more space for any helicoils.
Found bolt with same allen socket size, cut it to size and voila - fixed. With threadlock it won't go anywhere. Drilled out stator hole to 6.5mm