Alternator rotor removal

[pete]

Hi all,

I'm trying split my crankcases to check the gearbox out. It's an '81 GS450.

Anyway, I'm following my Haynes manual, and I'm at the point of removing the alternator rotor and I'm stuck.

I've removed the bolt, but can't get the rotor itself off. I don't have a slide hammer so I tried the dowel trick instead. Interestingly enough, the thread on the swingarm shaft is a perfect fit for the thread inside the rotor, but all I've succeeded in doing is compressing the dowel down into the hole.

The dowel I used just barely slid inside the hole (the manual says the bigger the better).

Any tips on where to go from here?

I've done a search, and the only tip I've found was to use the special tool, is that my only hope?

Pete

[Carter Turk]

You should be able to split the cases without touching the rotor or crank.

No need to take it off, if just trying to get at the gearbox.

[pete]

Bloody Haynes manual!

Hmmm... any tips on removing the dowel that's compressed and jammed in there now? :-)

Pete

[hungryman]

Carter is right about not having to remove the rotor to split the cases.

If it was my project, however, I would remove the rotor to replace the crankshaft seal on that side. I would replace ALL of the seals in a 25 year old motor if I went through the trouble to split the cases.

As for the dowel, I'm not sure what you did or what it looks like.

[pete]

Thanks Hungryman, good point...

I already used replacing the gaskets etc. as extra incentive to split the cases, but didn't think about things like that.

It's hard to describe the dowel situation and even more impossible to photograph it.

Basically, I inserted the dowel into the hole in the rotor, then used the thread on the swingarm shaft to screw it in and try to get the rotor off.

The dowel looks like it may have even gone inside the thread of the bolt that holds the rotor on.

The only thing I can think of doing at the moment is using a fine drill bit and very gently trying to drill the dowel out, but that thought scares the crap out of me given that I can't see what I'm doing in the hole.

[pete]

Ok, gonna havta do the scary thing and gently drill the dowel out. Only thing I can do to clear up the hole... probably a vacuum afterwards will help as well.

[pete]

Well, I've managed to clear about 90% of the dowel out.

As I feared, it looks like it just compressed all the way into the hole for the bolt. Yes, I'm an idiot...

Anyway, I still have to find a way to get the rotor off, especially as I now need to get the rest of the dowel out of there!

I might have to go talk to a dealer as to the best tool to use...

[hungryman]

Well, I've managed to clear about 90% of the dowel out.

As I feared, it looks like it just compressed all the way into the hole for the bolt. Yes, I'm an idiot...

Anyway, I still have to find a way to get the rotor off, especially as I now need to get the rest of the dowel out of there!

I might have to go talk to a dealer as to the best tool to use...

Good idea. You can pull the crank and rotor as a unit and take that to the dealer if you dont want to take the cases. That's what I did. They pulled the rotor off for free.

[pete]

Good stuff! Always good to get something done for free :-)

I'll have to get some bits and pieces along the way, so maybe if I take it when I'm doing some purchasing they might be kind enough not to insult me too much as well!

[hungryman]

Good stuff! Always good to get something done for free :-)

I'll have to get some bits and pieces along the way, so maybe if I take it when I'm doing some purchasing they might be kind enough not to insult me too much as well!

The guys at my dealership are great. It's not too insulting to have them pull it. If you don't have the correct tool forgetaboutit.

[pete]

Cool. Unfortunately I've moved to the other side of the city from the dealer I used to use, so I'll have to try one of the ones up here and see if they're any good.