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  • alternator rotor removal

    Just wanting to check before I break something. I am trying to remove my alternator rotoe off of my XJ to replace the seal behind it. I have put the bike in gear and trying to step on the brake while I try to remove the bolt holding it, but it's still trying to scoot the bike forward. I also tried using the box end of a wrench and a hammer on the wrench like an impact... still not budging. I don't have the special tool to hold this thing. I have thought about puting a bar through the spokes of my back wheel to hold it still, but I'm not even sure I'm turning this bolt the right way. Is it regular threads or reverse? All this oil buildup on the plate has started making my headlight dimmer at idle... didn't use to.
    Try your hardest to be the kind of person your dog thinks you are.

    You can live to be 100, as long as you give up everything that would make you want to live to be 100!

    Current bikes:
    '06 Suzuki DR650
    *'82 XJ1100 with the 1179 kit. "Mad Maxim"
    '82 XJ1100 Completely stock fixer-upper
    '82 XJ1100 Bagger fixer-upper
    '82 XJ1100 Motor/frame and lots of boxes of parts
    '82 XJ1100 Parts bike
    '81 XS1100 Special
    '81 YZ250
    '80 XS850 Special
    '80 XR100
    *Crashed/Totalled, still own

  • #2
    Sorry... meant to send this too




    Tod
    Try your hardest to be the kind of person your dog thinks you are.

    You can live to be 100, as long as you give up everything that would make you want to live to be 100!

    Current bikes:
    '06 Suzuki DR650
    *'82 XJ1100 with the 1179 kit. "Mad Maxim"
    '82 XJ1100 Completely stock fixer-upper
    '82 XJ1100 Bagger fixer-upper
    '82 XJ1100 Motor/frame and lots of boxes of parts
    '82 XJ1100 Parts bike
    '81 XS1100 Special
    '81 YZ250
    '80 XS850 Special
    '80 XR100
    *Crashed/Totalled, still own

    Comment


    • #3
      Gettin' Torqued!

      Hey Tod,

      The Engine rotates CCW from that viewpoint, and I'm pretty sure the bolt is a standard right hand thread. Try putting a nice piece of WOOD in the spokes, won't hurt the rim or frame like a hunk of metal!! And get a torque wrench, or breaker bar. ALso, try squirting some liquid wrench or equivalent product around it, let it set for a while, then tap it good with a hammer a few shots on the end of the bolt, spray it again, tap again, that helps the penetrating stuff to get in!!!

      Can't remember or find it right now, but I think it's got like 40 or more lbs' of torque holding it on!
      T.C.
      T. C. Gresham
      81SH "Godzilla" . . .1179cc super-rat.
      79SF "The Teacher" . . .basket case!
      History shows again and again,
      How nature points out the folly of men!

      Comment


      • #4
        Try using an impact gun on it if you have access to one. If not, try striking the end of the ratchet handle with a hammer when you are trying to loosen the bolt. Sometimes the shock of the impact will break it loose. There is a special tool designed to to pull the rotor off the shaft, but a three jaw puller will work. Leave the bolt in the end of the crank, but loosen it a few turns. Place the end of the arbor against the bolt. That will prevent the arbor af the puller from damaging the threads in the end of the crankshaft. Once it pops free, then it will slide right off. The end of the crankshaft is tapered. I pulled the rotors off two XJ engines that way.

        Comment


        • #5
          not trying to hijack this thread, but what's the secret to pulling the cover itself? mine won't budge, and i'm having the same problem(leaking oil). cheers, mark
          79 xs1100F
          75K and counting...
          76k...
          79k...
          80k...
          86k...

          Comment


          • #6
            *%@$# HIJACKER!!

            lol.. Just Kidding. I had to use a rubber mallet on mine and lightly hit it back and forth on the sides to get it to finally "Crack open". If you look at that picture of mine, you will notice 2 copper dowel pins on each side of the case. One at the arrows beginning, and one on the other side across from it. I think the gasket just gets stuck after so long.
            After you get the cover off, before you go tearing apart the alternator rotor on yours, make sure you check and see that it's not the galley plug leaking. Again... if you look at my picture here, you will see it as a little silver circle with a pin on it directly under my rotor in the bottom of the case. It has an O-ring on it inside the block, and sometimes these will leak. Do a search on "Galley Plug" to find out more. I recently tried to remove mine and broke it.... had to replace it. It just pulls out, no threads or anything, and don't start the motor with your alternator cover off. The cover holds this galley plug and it MAY shoot it out and you will lose your oil. After I broke mine... I tried this... no luck. Had to drill out the center and screw a bolt into it then pull it out. It's that little "tit" that breaks off.

            Tod
            Tod
            Try your hardest to be the kind of person your dog thinks you are.

            You can live to be 100, as long as you give up everything that would make you want to live to be 100!

            Current bikes:
            '06 Suzuki DR650
            *'82 XJ1100 with the 1179 kit. "Mad Maxim"
            '82 XJ1100 Completely stock fixer-upper
            '82 XJ1100 Bagger fixer-upper
            '82 XJ1100 Motor/frame and lots of boxes of parts
            '82 XJ1100 Parts bike
            '81 XS1100 Special
            '81 YZ250
            '80 XS850 Special
            '80 XR100
            *Crashed/Totalled, still own

            Comment


            • #7
              HiJack? Quick, call the Net Police!

              Hey there Portero,

              Well, first make sure ALL of the bolts are loosened and removed! Secondly, get a big rubber/plastic mallet. As you can see, this is NOT supposed to be an oil chamber, just a dust cover! However, either the PO put some good strong gasket sealer on there, or it's just gotten stuck/glued on !! Just need to hit it with the rubber/plastic mallet, or a piece of wood and metal hammer, until you are able to break the seal!!

              You could also try a wide flat screwdriver tip or similar tool, tapping it in between the parts to act like a wedge again to break the seal!
              T.C.
              T. C. Gresham
              81SH "Godzilla" . . .1179cc super-rat.
              79SF "The Teacher" . . .basket case!
              History shows again and again,
              How nature points out the folly of men!

              Comment


              • #8
                thx guys-its getting down to the nitty gritty here...don't wanna head to mexico with a leaky bike. TRBIG- thx for the tip, i'll check out the galley plug. are the o-rings readily available? time is tight.
                79 xs1100F
                75K and counting...
                76k...
                79k...
                80k...
                86k...

                Comment


                • #9
                  I couldn't tell you about on the net, but my local dealer could get them... it just takes him a couple weeks for OEM stuff (Not a Yamaha Dealer), but honestly, you could get a cheap o-ring set and probably find what you needed. If you have a Harbor Freight Tools around, I saw a nice set of them for cheap.... looked like enough O-rings to last a lifetime. Since time is short, I would go ahead and order the crank seal while you were at it. They are pretty cheap... 6 or 7 bucks a piece I think. I ordered 2 in case I muff one of them up. If you don't need them... maybe you can return them. If not... you could probably at least get your money back from someone on here. I know it was the same part number for my '82 XJ as it was for a 78 XS motor.
                  I finally got that nut loose. I pulled hard enough that I thought I was going to break something. I used the box end of a 17mm and the box end of a bigger wrench on that one for a breaker bar... and heard a loud POP!!! Luckily it was just the bolt breaking loose. I bet the motor turned at least 1/2 a revolution back when the bolt came loose. Tomorrow I have to borrow a pulley puller. Anybody have teenage kids?? Can you find any of your tools? Sigh.... unfortunately... even after telling my oldest to NEVER touch my tools again... I still find em when I mow...

                  Tod
                  Try your hardest to be the kind of person your dog thinks you are.

                  You can live to be 100, as long as you give up everything that would make you want to live to be 100!

                  Current bikes:
                  '06 Suzuki DR650
                  *'82 XJ1100 with the 1179 kit. "Mad Maxim"
                  '82 XJ1100 Completely stock fixer-upper
                  '82 XJ1100 Bagger fixer-upper
                  '82 XJ1100 Motor/frame and lots of boxes of parts
                  '82 XJ1100 Parts bike
                  '81 XS1100 Special
                  '81 YZ250
                  '80 XS850 Special
                  '80 XR100
                  *Crashed/Totalled, still own

                  Comment


                  • #10
                    "Now THAT"S funny!"

                    even after telling my oldest to NEVER touch my tools again... I still find em when I mow...
                    Oh Lawdy... how true! (I remember my father saying the same thing!)
                    "Damn it Jim, I'm a doctor, not a mechanic!' ('Bones' McCoy)

                    Comment


                    • #11
                      Hey Portero...

                      I got my seal installed last night and everything looks good, so I have this extra seal I can send to you if you need it quickly. Just let me know. Probably wouldn't take more than a day or 2 from here to there. I am leaving for a week tomorrow, so let me know pretty soon if you do.

                      Tod
                      Try your hardest to be the kind of person your dog thinks you are.

                      You can live to be 100, as long as you give up everything that would make you want to live to be 100!

                      Current bikes:
                      '06 Suzuki DR650
                      *'82 XJ1100 with the 1179 kit. "Mad Maxim"
                      '82 XJ1100 Completely stock fixer-upper
                      '82 XJ1100 Bagger fixer-upper
                      '82 XJ1100 Motor/frame and lots of boxes of parts
                      '82 XJ1100 Parts bike
                      '81 XS1100 Special
                      '81 YZ250
                      '80 XS850 Special
                      '80 XR100
                      *Crashed/Totalled, still own

                      Comment


                      • #12
                        TRBIG-was it easy? thats my job 4 tonite. already hv a seal, but thx anyway. o-ring went in, still seeping. good advice about harbor freight. any tips/tricks?
                        Last edited by portero72; 03-01-2006, 11:37 AM.
                        79 xs1100F
                        75K and counting...
                        76k...
                        79k...
                        80k...
                        86k...

                        Comment


                        • #13
                          Toughest part for me was getting the rotor off (Had to run a piece of wood through the back rim to stop it so I could loosen the bolt) then a pulley puller got the rotor off finally. Then, taking the old seal out was way harder than puting the new one in. Be careful so you don't mess up the machined seal seat on the case. When I tapped the seal in, since the seal is coated with rubber, it sheared a little sliver of rubber off the outside edge, but seems to be holding fine. After I got the seal flush with the case, I tapped it all the way in with the back side of a center punch. Just be careful, and you should be fine. Good luck and let us know.

                          Tod
                          Try your hardest to be the kind of person your dog thinks you are.

                          You can live to be 100, as long as you give up everything that would make you want to live to be 100!

                          Current bikes:
                          '06 Suzuki DR650
                          *'82 XJ1100 with the 1179 kit. "Mad Maxim"
                          '82 XJ1100 Completely stock fixer-upper
                          '82 XJ1100 Bagger fixer-upper
                          '82 XJ1100 Motor/frame and lots of boxes of parts
                          '82 XJ1100 Parts bike
                          '81 XS1100 Special
                          '81 YZ250
                          '80 XS850 Special
                          '80 XR100
                          *Crashed/Totalled, still own

                          Comment


                          • #14
                            thx for the tips...wish me luck....mark
                            79 xs1100F
                            75K and counting...
                            76k...
                            79k...
                            80k...
                            86k...

                            Comment

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