Clinic
You CAN do it...
Fixing the Starter Spin Problem |
Written by Randy Fox (Randysgym) | |
Wednesday, 10 October 2007 | |
Page 3 of 6
Disassembling Parts
This project can be done without draining the oil from the engine, as long as you do not upright the bike. This means: Leave the bike leaned over on its side-stand. Once the generator cover is loosened, you may lose a few tablespoons of oil, but unless your bike's lean-angle has been altered by lowering the suspension or something, no significant amount should spill out. Tip: If you have lowered your suspension, you can increase the lean-angle by putting the tires on something very stable, roughly the same height as the amount you’ve lowered your bike. In other words, if your bike's rear suspension is lowered 1.5”, you can lay a short 2x8 board flat under the rear tire. Unbolt the right-side floorboard bracket. It is held on by two, button-head bolts going into the frame. Be careful to support the floorboard assembly as it comes loose. This assembly is still attached by the hydraulic hose and the brake light wiring. Use a tool box or other support to lay the floorboard assembly onto. Warning: If you just let the floorboard assembly hang by the taillight wires or hydraulic hose, you run the risk of breaking the wires to the switch, or damaging the switch itself. Remove the front exhaust pipe. Next, remove the two bolts holding the generator’s oil-delivery-pipe to the right-side of the engine. It is much easier to remove this pipe and the generator cover as one piece, rather than trying to separate them while on the engine. See photo below.
Unbolt, and then remove the generator cover and oil-delivery-pipe as a unit. Also note: there is a long bolt near the bottom of the cover that has a copper or aluminum washer. Keep track of (or replace) this washer, where it goes, and which bolt it goes with. Tip: The generator cover is magnetized to the generator rotor. To remove the generator cover, you need to un-bolt it, pull or tap it free of its gasket seal, work it off its alignment dowels, and then pull the cover free with enough force to overcome the magnetic force.
Remove, and keep track of, the two alignment dowels. They have a tendency to slip out of your hands and fall into very frustrating places, so be careful. Now that the cover is off, you can see what’s inside. Remove the generator rotor center bolt. The bolt is on very tight, unless it has come loose. To get the bolt loose you may need a long breaker-bar socket wrench or an impact wrench. In addition, you may need to hold the shaft from turning. This can be done anyway you want. Here's some suggestions:
Finally, remove the generator rotor. It is only held on by friction, but it can be stubborn unless it has already come loose. See Caution Tip below. To break the friction seal between the rotor and its shaft, do any combination of the following:
Caution Tip: The generator rotor is heavy. If the center bolt is not in when the rotor breaks loose from the shaft, it could fall out quickly. Take precautions to prevent injury to people, your bike, and the rotor by laying down a padded landing beneath the area, being ready to catch it, and keeping clear, as best you can.
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