How do I replace my alternator rotor?

[crazn]

First, my bike is a 1981 XS650S.

I'm think'n I can do this but I am not sure what I need to dissassemble to remove the rotor. I've got the removal tool. Do I need to take the side panel off or can it be removed through the round access panel? Do I just start unscrewing everything until I get to the rotor?

Any help is appreciated. Maybe there is already a thread that I couldn't find.

[pamcopete]

crazn

Start by putting the bike in second gear.
Remove the following:

1. Shift lever.
2. Foot peg.
3. Loosen the clutch cable at the handle bar perch.
4. Remove all screws holding the side cover on. Check for screws on the bottom of the cover.
5. Remove the side cover.
6. Remove the rotor brushes.
7. Remove the two long screws holding the stator cover.
8. Remove the stator cover. Be careful and don't bend the wires unnecessarily.
9. Sit on the bike with it in second gear holding the brake on and reach down with a 17mm socket / ratchet and loosen the rotor shaft nut.
10. Using the rotor puller tool, remove the rotor.

Notes: 1. You will probably need an impact screwdriver to loosen the screws holding the stator cover on. You will probably break the head off of at least one of them. MikesXS has replacements, of course.

2. Check the torque for the rotor nut when you reassemble it. It is lower than you would think.
3. Be very careful when handling the stator wires as they are 30 years old and brittle.
4. DO NOT clean up the stator. Just leave the dirt and crap on it as any attempt to clean it up will probably remove some insulation from the 30 year old wires and cause an expensive short.

[crazn]

Thanks. I will follow your instructions and report back.

[crazn]

I worked on the bike with my son last Wed. and followed your instructions. Success!! I now measure 14 volts at 3,000 RPM. My only goof was I didn't think ahead and put the bike in 2nd before I took the side panel off. The two long screws threatened to stop progress, but the impact screwdriver I borrowed from my neighbor worked like a champ. Thanks again.

[pamcopete]

crazn

Great! I edited the instructions for the next guy to start by putting the bike in second gear!

[dzais]

Hi all,

I am doing a complete rebuild of an engine and had a similar question about installing the alternator rotor. Does it only go on one way? By that i mean, do you have to take into consideration the timing marks when installing the rotor? Do you have to make sure that the pistons are at TDC when you install the alternator and line up the marks with the stator?

Thanks,
David

[punkskalar]

No, it is keyed onto the shaft. It only goes on one way.

[waterboy]

Thanks for posting this Pete. I used this today to change out my rotor. I must have done something wrong because now when I turn the key it blows the fuse ( single glass style stock '77 XS) Any Ideas ?

[givememytoys]

Here is the procedure I used today to remove the rotor on my 82 XS650,not sure where to post this but here goes..

First I losened the clutch cable on the bars then removed the shifter then all the allen bolts on the left side cover. Then removed the cover...



Then I removed the #2 Phillips head screws that hold in the brushes on the stator. Then pulled out the brushes..



Next was to get my trusty impact screwdriver with a #3 Phillips bit. I went at it easy I didn't want to break the screws in half. They came out pretty easy with this tool.



I grabbed the stator with both hands and wiggled it back and forth gently until I felt it get loose then slid it right off....




Up next I shot a bit of penetrating oil on the nut and shaft and let it set for a few while I got the stuff for the next step.

The handy dandy DeWalt 1/2 impact made this step easy... I still went at it easy, these parts had not been taken off since new judging by the crust and corrosion on them.




Then I grabbed the rotor removal tool I got from Mikes for $10.00??



I also shot some penetrating oil on the threads and cleaned them up a bit. Then threaded the 1 st part of the tool on not to tight just real snug.




Then a tad more oil on the threads of the tool and installed the second part of the tool.




Then I got a 15mm socket and a 3/8 ratchet.




Twist twist twist and pop it came off...... Sweet!!!






DING DING DING we have a looser.. 1.6-1.8 ohms. It needs to be 5.0 or more to charge well..





Thanks for the break down on ths Pete it made this job easy....



I thought pic's would help others....

[jeffery]

Thanks for the walk through and good pics too. Will be very helpful to many when it comes time to remove.
Jeffery

[givememytoys]

Not a problem I know I find stuff easier with pic's..

[givememytoys]

Sweet!!!!!
The rotor came today and I installed it!!!!

I got it from Tim Parrott ent. Dude did me a big favor and shipped the new one before he received my core. Not normal practice but he took a look at my feedback on eBay and said sure I'll send it right out....

Anyhoo here is what the new one looks like..





So I stuck my ohm meter on it and I was happy..




Then I popped the rotor on the bike.




One note that I want to make about installing the stator. It fits snug between the tabs on the engine case,so I had to (((( lightly )))) tap in on with the plastic handle of a screwdriver.
Make sure it is lined up right and square. Really light tapping go easy. I'm not sure if yours will fit as tightly as mine. Like I said before as far as I could tell mine had never been off before. Then I installed new brushes.

Then I installed all items in reverse order of disassembly..



Here is the results....

[650xs]

I just got a new rotor and stator in the mail, but I forgot to get a puller. I'd really like to get it done over this weekend. Is there a comparable rotor puller I might be able to pick up locally? Do they come is specific sizes?

[xulf13]

Great write up. I have to check my rotor soon as my battery is not keeping charge. It's a new Gel battery. When I was riding the other day the bike was sputtering and i had to turn the lights off in order to keep it running and make it home. I would only turn the lights on when I saw a car in the distance. When I got home I check the battery and I had 11.86 Volts. I wanted to check the rotor ohms, but where exactly are you pluging in to get your readings for the rotor? and is there a way to check without removing the rotor?

Thanks.

[xulf13]

Never mind. I read Curly's Article and figured it out. I'm going to start my own thread. Sorry to highjack this one.