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garynortheast Profile
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Registered: 06-2005
Location: Mid Wales
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Re: Charging problems


Ok well I'm back onto this now.
A friend of mine came over with an oscilloscope and after hookijng it up to the charging system we determined that the alternator was knackered.
So finally today I've started on the business of getting the old one off and replacing it with a new one which I shall buy from Electrex World, hopefully next week. A brand new one will cost me around £75 and well worth it for the peace of mind I'd say bearing in mind that I'm planning on going on a fairly ambitious ride this summer - see the Rides section for stuff about that one.

A few pics of progress so far....

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Seat and side panels off.

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Fairing lowers off and battery out.

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Clutch/alternator cover off.

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Alternator locked ready to undo the centre bolt - crude but effective!

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A few sharp clouts with a hammer to loosen the loctite covered threads of the centre bolt.

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Bolt undone.

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Alternator now ready to be removed - except that I need the puller to remove the rotor first, hence all the measurements on the picture. Anybody got anything suitable in their toolboxes?

Here's a picture of the tool I need.
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More on this as the job progresses.

I'm going to be getting on with a number of other jobs on the bike this winter too, so I'll post up pictures and a few words about them as I go on with it.

---
Gary.

3/1/2009, 17:17 Link to this post Send Email to garynortheast   Send PM to garynortheast MSN
 
madmickyb Profile
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Re: Charging problems


just spotted your post gary !! i'l try knocking something up for ya in the next couple of days mate !! emoticon


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3/1/2009, 19:35 Link to this post Send Email to madmickyb   Send PM to madmickyb
 
garynortheast Profile
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Re: Charging problems


Mick you're a star mate!! Thanks for that. emoticon

---
Gary.

3/1/2009, 21:38 Link to this post Send Email to garynortheast   Send PM to garynortheast MSN
 
banditmax1988 Profile
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Re: Charging problems


If mick doesnt knock you something up have a look at, [sign in to see URL]
4/1/2009, 20:42 Link to this post Send Email to banditmax1988   Send PM to banditmax1988
 
garynortheast Profile
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Re: Charging problems


Thanks for that Banditmax, very useful link. It was so cheap I couldn't say no and if it lasts just long enough to get the rotor off this once then at that price who cares! emoticon

Mick don't worry about making one up. Your offer was hugely appreciated though. emoticon

---
Gary.

4/1/2009, 21:32 Link to this post Send Email to garynortheast   Send PM to garynortheast MSN
 
garynortheast Profile
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Re: Charging problems


Well the puller I bought on ebay for the princely sum of £[sign in to see URL] delivered (as recommended by Banditmax emoticon ) arrived a week or so ago. This morning I went into town and bought three better looking bolts to use with it along with some stout washers to put under the heads. Then this afternoon it was out into the garage to get the rotor off the alternator.

I'd already removed the clutch/aternator cover and the centre bolt so I put the centre bolt back in about ¾ of the way so that the centre bolt of the puller had something to push against whilst leaving enough room for the rotor to come away.
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Then I attached the puller.
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I locked the whole affair up by sticking the bike into gear and putting my foot on the rear brake. Once all the slack in the transmission had been taken up I kept up the pressure on the socket and tommy bar while giving a few sharp taps to the end of the knuckle on the bar.
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Once the rotor had come free I took the centre bolt out of the puller to give me room to remove the alternator bolt. Then I used the puller as a handle to lift the rotor clear. It takes a bit of effort as the magnets in the rotor are pretty strong.
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Once the rotor is off you can then see the three cross head screws retaining the stator. I shall replace these with s/s dome head allen screws.
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I needed an impact driver for the screws but as I didn't have one I impovised with a hexagona screwdriver extention, a small ring spanner and a small hammer.
My thanks, incidentally, to one of my six year old daughters, Eleri, for the rest of the photos.
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Once the three stator screws were undone the stator lifted out. I undid the cable retaining clamp and eased the rubber seal around the wire out of it's slot. I will have to get this off of the old stator intact in order to fit it to the new stator I'm going to buy from Electrex World.
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Here's a picture of the seal.
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And lastly there's a spacer behind the stator which it would be all to easy to lose!!
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I shall be phoning about the new stator tomorrow so hopefully will have that in my hands by early next week. I'll post up on progress when that happens.

---
Gary.

20/1/2009, 22:54 Link to this post Send Email to garynortheast   Send PM to garynortheast MSN
 
garynortheast Profile
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Re: Charging problems


A quick update on this. Can't get my new stator till next week as Electrex World make them in batches for different bikes. They're making a batch suitable for my bike next week. Good news is that the rubber grommet I thought I would have to fit is already fitted on the new stator wires when it arrives.

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Gary.

28/1/2009, 21:27 Link to this post Send Email to garynortheast   Send PM to garynortheast MSN
 
gsxr400rr Profile
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Re: Charging problems


Great pics Gary and well done on a crackin job so far

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garynortheast Profile
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Re: Charging problems


Finally ordered my new stator today, should be with me by the end of the week. £90 including postage.

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Gary.

10/2/2009, 23:05 Link to this post Send Email to garynortheast   Send PM to garynortheast MSN
 
garynortheast Profile
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Re: Charging problems


My new alternator arrived a few days ago so I got out into the garage and fitted it yesterday. Ran out of time before I had the chance to finish the job so back out there this afternoon to torque the rotor bolt up, fit the clutch and alternator cover, put the new filter on the bike and some fresh oil.

Put the battery back on the bike (it's been hooked up to my Accumate battery charger while I've been working on the bike) and started it up. Took about 30 seconds of cranking it over to get it started, it's not run for nearly 4 months. Once started I slowly took the choke off and wound the tickover screw up to a fast idle till it was warm. Then back down to normal tickover level to get it nice and hot.

It was so nice to hear the old girl running again!

I've got a few pics I'll post up when I get the chance.


---
Gary.

23/2/2009, 19:19 Link to this post Send Email to garynortheast   Send PM to garynortheast MSN
 


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