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Fixing the Starter Spin Problem

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Written by Randy Fox (Randysgym)   
Wednesday, 10 October 2007

Disassembling Parts

 

Generator marked, Yamaha Road Star

 

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.

 

Stator oil pipe, Yamaha Road Star

 

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.

 

Stator oil tube, Yamaha Road Star

 

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:

  • Put the transmission in gear. Tip: Be sure you prevent your bike from rolling as you torque the rotor onto the shaft. For instance, you could have someone stabilize the bike for you while you tighten the bolt.
  • Use a Yamaha generator rotor holder tool (sheave holder).
  • Use an adjustable, open-end (crescent type) wrench on the rotor to counter much of torque.
  • Use an impact wrench, as long as you can set it, and your compressor, to at least 115 ft-lbs of torque.

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:

  • Thread the center bolt most of the way back in (by hand), but leave the bolt-head sticking out from its seat. Then smack the bolt with a plastic dead-blow hammer.
  • If you don’t have a dead-blow hammer, you can rest a piece of lumber against the bolt and rap the wood with any type hammer.
  • Heat the center area around the generator bolt (but not the shaft or bolt, as best you can) using a propane torch. Then do one of the above. Warning: Do not overheat.
  • Try using a dead-blow hammer or piece of wood to rap around the sides of the rotor.
  • Try removing the center bolt of the generator rotor, and using one of the hammer tricks listed above applied directly to the center portion of the rotor.
  • Caution: Do not use excessive hammer force. To avoid damage to the generator shaft bearings, pull out on the rotor, as you rap it to free it.
  • Use a large wheel/gear puller.

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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