So i think im going in the right direction!

[GTXS1100]

So as most of you have been following me on my road to getting my bike going, heres what i have found. The charging system on my bike sucks and wont charge but as i was getting ready to give up tonight i said well lets pull the cover of the generator and see what it looks like been a while since ive been in there. And boom i think i may have found my problem the coils look like they have been rubbing on the rotor. I have others so its no big deal so i start prying alittle on the rotor to see if it will come off easy. No go. But i know what you all are thinking i didnt F*#K anything up. I realized that if you have the right sized bolt you can press it off. ok. But what im asking the group is does anyone know what size of bolt and thread count i need or do i need a special tool? Finaly feels good to be making some head way.

[GTXS1100]

The manual just said to use a universal magneto remover tool and holder but i do not have one. Does anyone know of any other way to get it off there?

[DiverRay]

It IS a removal tool, but I don't have mine here, so I can't help with the size. I do know it was available about four years ago, and it fits the 750/850 as well as the XS11, IIRC. I think mine was about $9.95, so it will probably be about $15.95 today. You should be able to order or find one at almost any good motorcycle shop.
If you heat up the rotor with a propane torch, it will help.

[Barnfresh]

Flywheel Puller #35-0091. It's a 16mm x 1.5 thread.

http://www.partsnmore.com/parts/yamaha/xs1100/?filters[category]=tools

[bikerphil]

IIRC, it's 16MM, 1.50 pitch thread

[Rasputin]

I went to the local John Deer dealer and bought the bolt needed from them. About $2.50. IIRC then Bikerphil is correct on the sizing. I lent mine to Rooster and he has yet to return it so I can not check for you.

[GTXS1100]

Thanks big help.

thanks thats a big help exacly what i wanted to know. Im going to the hardware store today to look hopefully i can find something that will work.

[GTXS1100]

Its fixed!!!

Found the bolt i needed at ace hardware.. Swoped the rotor from another bike and put on the new generator i got from ebay and whala it was charging. Now just got to do a little work on fine tuneing the carbs and ill be riding soon. Also my head light relay is bad any one know where a good place to find one is?

[natemoen]

Also my head light relay is bad any one know where a good place to find one is?

If you are sure it is not working you can just eliminate it.

[GTXS1100]

I have it bypassed with a jumper wire was just wondering if someone knew of a place to get one if they arent too expencive.

[bikerphil]

The relay is totally (in most cases) fixable, hardest part is getting it open. Once you get it open, the problem should be self evident, usually a broken solder connection, YMMV.

Or you can get a used one from eBay, the 78-79 ones are different than the 80-81 type.

The method for bypassing is to jumper the red/yel and blu/blk wires at the harness connector after removing the relay. Headlight will now come on with the key power.

[DGXSER]

I have a spare laying around. I may be jumping mine out primarily because of the Diode I think. Mine works fine most of the time, but every now and then it refuses to come on. Healdight and all dash lights are a no go. But then magically come on. So has to be either the diode or the relay going out.

[cywelchjr]

Also, are you SURE it's the relay and not the diode in the harness that's the problem? Unlike the 78 and 79's that have the diode built into the relay, the 80+ bikes have the relay in the harness as a separate item and it can go bad (I've not had it go bad on my XS11, but my XS400 has had TWO of them go bad, the original and an OEM replacement), it's pretty easy to replace if that's the case, but you have to find the relay in the wiring harness and check it to be sure. If it's bad, any 1 amp 14 volt or so diode will do to replace it.