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July 24, 2014, 10:48:46 AM

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Author Topic: 500es alternator rotor  (Read 1190 times)

MattL

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500es alternator rotor
« on: June 12, 2008, 02:18:39 PM »
I've been having a really tough time trying to remove my alternator rotor. I need to get into my gearbox to check a problem with my shifter. I already figured out that it is not the ratchet adjustment or the gear operator selector. In any case, I tried removing the 1" rotor nut, by holding the rotor with an oil filter wrench to no avail. I even used two 2 foot pipes on the oil filter wrench and wrench holding the nut. The oil filter wrench actually broke before the nut even budged! I believe I marred the surface of the rotor too much for it to function so I have to order a new one. Has anyone had this trouble before? I have a 2002 500es with only 600 miles on it. Bought off of Ebay with the shifter problem. Any suggestions would be appreciated.

Bankerdanny

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Re: 500es alternator rotor
« Reply #1 on: June 12, 2008, 02:53:54 PM »
I pulled mine last month so I could remove the primary.

It was definitely tough. I sat on the bike and used the brake lever to keep the primary from rotating.

If that doesn't do it, you could use a wedge of wood in between the drive chain and the rear sprocket. That will stop the rotation and the wood should be soft enough to not damage the chain or sprocket teeth. I used this approach when I reinstalled the rotor so I could tighten the nut.
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MattL

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Re: 500es alternator rotor
« Reply #2 on: June 12, 2008, 03:09:11 PM »
I tried the brake technique, still didn't work. Hopefully, the wood will work. Do you think heat will do anything? I could heat up the rotor with a torch.

Bankerdanny

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Re: 500es alternator rotor
« Reply #3 on: June 12, 2008, 04:29:53 PM »
Don't. You risk damaging the stator.
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Bankerdanny

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Re: 500es alternator rotor
« Reply #4 on: June 12, 2008, 04:35:54 PM »
I also doubt that you damaged the rotor enough that it won't work. If you gouged up the outer face maybe (the part that spins inside the stator). But the front where the nut is doesn't affect the operation of the alternator.

The nut will be very tight to prevent it from backing off. I recommend a trip to the hardware store for a large wrench and a plastic dead blow hammer.

The nut that holds the countershaft sprocket in place is even larger than the one on the rotor. I bought a box end wrench at Sears to get it off. I think it is 1 1/4inch.
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resteveb

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Re: 500es alternator rotor
« Reply #5 on: June 12, 2008, 04:49:23 PM »
My advice would be to purchase the proper tools. They don't cost that much and you will use them again.

MattL

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Re: 500es alternator rotor
« Reply #6 on: June 12, 2008, 07:51:38 PM »
How about an impact driver?

Bankerdanny

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Re: 500es alternator rotor
« Reply #7 on: June 12, 2008, 08:56:47 PM »
That would probably work, although slippage might still be an issue.

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ERC

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Re: 500es alternator rotor
« Reply #8 on: June 12, 2008, 10:09:28 PM »
Put bike in 1st gear foot on brake and use a 1/2" drive air wrench. works everytime.
2-57 Apaches, 2-57 Trailblazers, 60 Chief, 65 Interceptor, 2004 Bullet, 612 Bullet chopped.

dogbone

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Re: 500es alternator rotor
« Reply #9 on: June 14, 2008, 04:55:21 PM »
I used an air impact worked real fast. I also have a good used 4 wire alternator $50.00
Iff'n you might need one  :o'
99 Enfield Bullet 535
a man isn't drunk,if he can lie on the floor without hanging on