Bike Quit!

[BA80]

There is a plug behind the fuse panel with 3 large white wires and a smaller yellow wire. That is the one you need to check as well as the plug to the regulator.

The actual puller for the alternator rotor is just a large bolt. I don't recall the size but someone here does I'm sure.

Sorry I meant to say in the last post that the field coil should be mounted solidly in it's aluminum cover. Yes, that could be a problem.

[IanDMacDonald]

You're doing a lot of what I used to do: throwing-out a lot of guessing before measuring. Take a breath, measure what is supposed to be measured, and report back. Loose windings could be bad. Oil sloshing around is not good. I went through a very similar issue, so I'm familiar with what is, and what is not an issue.

Second, StepToe has a great video on removing the alternator. I believe it's a 16mm bolt, and maybe 1.25 or 1.5 pitch. Don't use jaw pullers.

[crazy steve]

In 40 years of auto repair I have never had oil conduct electricity and cause a short. Oil is actually a pretty good insulator.

It's an excellent insulator... Almost all utility transformers are oil filled for both insulation and cooling. And more than a few bikes have alternators that are in the crankcase and running in that oil.

[ginger]

Bike Quit

Anything wrong with using some 2 part epoxy to repair the field coil?

[BA80]

I would just replace it. I don't know if you've checked for grounding of the field coil and/or stator to the cover but most likely it is grounded causing your no charge condition.

There's always one available somewhere and usually pretty cheap.

[BA80]

http://www.ebay.com/sch/i.html?_odkw...0063&_from=R40

[IanDMacDonald]

Again, can we see some numbers from the resistance tests?

[ginger]

Bike Quit

Well, i tried the resistance tests tonight, i realy dont know what im doin, I borrowed an analog tester and all i could get from whit to white off the stator was the same thing as when you touch both leads together??? I think I need some adult supervision with the testing stuff

[CaptonZap]

Who's the Luddite that you borrowed the meter from?

Most analog meters of the "less than $500 per copy" do not accuratly measure the ohms that you are looking for.
That said, you don't really care if is is accurate to a decimal place.
Put the meter on the lowest ohms scale, and measure from one white to another, and remember that reading. Leave one lead on one white, and put the other lead on the other white. Is that reading close to the same as the first reading? If it is, take the lead that you didn't remove the first time, and touch it to the other white wire. They should all be down around 1 or 2 ohms. If you have it on a higher ohm scale, you may not notice any needle movement. Put it on the lowest ohm scale
If it is close to the first two readings, leave one lead on a white wire, and touch the other lead to the case. The needle should not move.
If all of those things happen, you are in like Flynn. And yes, you can use epoxy to secure the windings. Just don't use an epoxy that is metal filled. (Like JB Weld)
Put it back together and look for another cause of your low voltage.
Hey, I have an idea!!! Since you have the meter, when you get the connecters all cleaned and siliconed, start the bike and measure the DC voltage at the battery. The red lead goes to the positive, and the black goes to the negative. (Analog meters do not handle reverse connections well.)
As the RPM get up to 2500 or so, the voltage should increase to over 13 V DC. If it doesn't you may have a bad regulator, and you can find test procedures in the manual on Catatonic Bug's web site.

CZ

[ginger]

Bike Quit

Well today after a 3 county search I found a 16mm 1.5pitch bolt to pull off the flywheel, I could not seem to make it thread in the hole, is this the correct size or am i doing something wrong

[IanDMacDonald]

That's the right bolt.

[ginger]

Bike Quit

The Bolt worked, I just had to use a little more force than I thought, I pulled out the leaking bearing, does this picture look like it should after the bearing is out, it appears something is not lined up inside there?

http://i98.photobucket.com/albums/l2...ps332d7a9a.jpg

This is my first time linking picts, hope it works

[TopCatGr58]

The Bolt worked, I just had to use a little more force than I thought, I pulled out the leaking bearing, does this picture look like it should after the bearing is out, it appears something is not lined up inside there?



This is my first time linking picts, hope it works

You had the right URL text, but the wrong codes...don't use the URL/Link type code, but the IMG codes [ img ]..photo link text/url.... [ /img ] I put spaces inside the brackets so that they would show here, but they do not have spaces.

Regrettably the photo is not directly INLINE with the crank so we really can't tell if the crank if off center with the crankcase opening!? But others with experience with this repair will hopefully chime in otherwise.

T.C.

[ginger]

Bike Quit

I was thinking it looks like the cases are mis alinged ,is that even possible?

[BA80]

Can you move that end of the crankshaft up, down or otherwise? see if you can pry it up with a big screwdriver or something.

Did the engine knock when running?