Help! Can't get magnet rotor off!

[mikail gransee]

This is what he sould have.

[LarsBloodbeard]

Thanks for all the advice, guys.  I decided to set it aside for a while and mull it over with my subconscious.  I'm going to pick up a carbide cutting disc for my dremel and try cutting down to that sleeve tonight.  I'll let you know how it goes...

[LarsBloodbeard]

I got it off!  I wound up drilling a small hole in the remaining collar and shoving an old precision screwdriver into it and an angle and hammering it around in a circle till enough of the collar was sticking out for me to get a wrench around.  Had a hell of a time getting the remains of the magnet rotor off... The woodruff key was mangled and split also.

Now to find a new nut and woodruff key.  Do you guys suggest Hitchcock's for bits and pieces like that?

[mrunderhill1975a]

Good job!  Hitchcock's would have the correct parts as would Nfieldgear.  There are several web-based stockist sites that could get the parts, but, from my experience, the web-based stockists may or may not have the best finished spares.

[mikail gransee]

I got it off!  Do you guys suggest Hitchcock's for bits and pieces like that?

GOOD JOB!   I find that Hitchcock's is about the best for in stock "need it now" items the are correct for your bike.

[The Garbone]

Very cool on getting it off.  I think Ace Hardware would have the woodruff key.

[AgentX]

ALL HAIL LORD DREMEL!!!

[LarsBloodbeard]

Thanks guys.  I couldn't find the woodruff key and collared nut on nfieldgear.com so I got them off Hitchcock's.  I've had a lot of issues with orders taking months to be fulfilled with nfieldgear anyway.

I had never ordered from Hitchcock's before.  Their prices and shipping costs are surprisingly reasonable!

I wound up getting an alternator set from ebay for only $60, including shipping.

[LarsBloodbeard]

Apparently when the magnet rotor catastrophically failed, it bent my output shaft.  I suppose it's not that surprising considering the carnage I witnesses after opening the primary case, including the fact that the output shaft was a bit mangled so I had to sand it down before I could even slide on the new rotor.  After putting it all together I checked the gap between the rotor and stator and it is tight on one side.  I rotate the engine and it's tight somewhere else.  Doesn't seem to be rubbing though.  So not bent horribly out of whack, but bent nonetheless.  I'd like to get a performance crank and throw in some new cams while I'm at it, but don't have the cash at the moment.  So I guess I'll risk riding it for a while...  Bad idea?

[baird4444]

you could remove the magnet to see if you have any out of round movement of the shaft. You might chuck up your magnet in a lathe to see if it is out of round. I took a couple thousandths off mine to make it perfectly round. easier to center as well. Are you using spacers?
You can cut strips out of a peanut butter jar or yogurt cups to use as gauges.
    Mike

[mrunderhill1975a]

My rotor is slightly out of round from the factory, about half the thickness of the plastic used in antifreeze container.  It has not noticeably caused any problem.

If your rotor doesn't hit the stator at some point, you should be OK.  Does your alternator produce approximately 47volts at the stator?

[LarsBloodbeard]

Hm, good point.  It could be the rotor itself that is out of whack.  I never thought of that.  I don't think it actually rubs, but the gap is too tight to squeeze in a piece of 2L bottle between the magnet and stator.  I'll pull it apart again and check that out.  Good thing I didn't fill the primary case yet!

Can't check the voltage as the barrel is disassembled right now (see pic).

[AgentX]

I have the same problem and question about my alternator.  I think the output is low owing to the wobble, whatever the cause.

I'm going to replace it with a new one (off an e-start model for higher output) and see if the wobble remains.  There's no sure thing that the new rotor is perfectly made, but it should help me eliminate causes.

If it's the crank that's off true, I'll just live with it until I rebuild the engine next year.

[mikail gransee]

I thought the same about mine..the shaft being bent but checked the rotor and found it not to be "true circle" hand to adjust the stator a couple of times to get a correct gap. Also recommend getting an "Boyer power box/ 8)regulator" one can have the best alternator but if your regulator is junk well....

[AgentX]

Also recommend getting an "Boyer power box/ 8)regulator" one can have the best alternator but if your regulator is junk well....

This is getting wierd--I just hooked up my powerbox.