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Discussion Starter · #1 ·
As some of you may remember from earlier postings, it sometimes happens that I get one or two bikes to fix that "my" local bike shop don´t want to work on. Old and neglected vehicles, more or less sad to look at. It started with a couple of CX-es. There have been some more, after that.



Right now there are one Yamaha XC 125 Beluga (real bag of sh-t), one XV535 Virago (same owner) and the latest of them all - a Honda VF750 S (Sabre for you over there) - clutch problem, to name one. Not especially fun, if I may say, but I´m learning a little, each time.



The Virago had a charging problem (among others) and with the help of some of you I traced it to be a stator failure (resistance readings and also output voltage). Bought a new aftermarket stator (Electrex) and today started the work of replacing it. Took the lhs cover off and what did I find? (As a sidenote - it´s pretty much the same thing as a non-CDI CX layout, in there.)



Wedged in between the tops of two of the alternator coils I found a fragment (~5 mm) of a 8 mm bolt / screw. No surprise (I think) that the output voltage figures were too low between two of the three cables. The bolt fragment had made some scores inside the the alternator rotor. No doubt had the bolt fragment damaged the insulation between the two coils.



The problem now (at least for me) is - from where did that fragment come? I checked closely and it doesn´t seem to be any problem with the rotor. Maybe I´ll find something if I take the rotor out?



I´ve seen some fried stators before, but this one is new to me - a foreign object inside the alternator.



You live and learn!!



Sture



P:S: I´m seriously considering to quit doing this - takes much more time than I can expect to get paid for. And what´s the fun with cleaning up other´s mess??



 

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That's a tough one, Sture. Maybe someone installed a longer bolt than speced, and a gear or rotor sheared just the end off. That may be hard to notice unless you get lucky.



I know what you mean about fixing other people's messes. It is one thing if you are doing it for yourself, but bailing out guys who don't appreciate the bike can get old. I have spent 3-400 hours messing with my own restorations and was happy doing it. But expecting someone to pay for 400 hours on a bike worth $1500, just can't happen. I am not talking about helping others out on their repairs, I do enjoy harassing Rickbert about getting things polished on his bike. And 4-5 hours is a lot different than 4-5 weeks of work.
 

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I think if an 8mm bolt protruded on to the moving part of the shaft on assembly

it would be damned hard to shear off by cranking on the starter.

Shearing an 8mm bolt aint easy !

My guess would be F.O.D. and it was picked up by the magnets in the rotor

during some previous work, went unnoticed and lodged in between the coils.

Try and get some history of previous work.

Inspect the casing by all means and see if the rotor magnets have been severely affected

by it, you dont want them breaking up cos you'll get the blame !!



I'd stop, tell the owner what you found, give him some options

and wait until he throws money at you before spending anymore time on it.

At least the old Viagra stators are easy to get at
 

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Discussion Starter · #4 ·
I think if an 8mm bolt protruded on to the moving part of the shaft on assembly

it would be damned hard to shear off by cranking on the starter.

Shearing an 8mm bolt aint easy !

My guess would be F.O.D. and it was picked up by the magnets in the rotor

during some previous work, went unnoticed and lodged in between the coils.

Try and get some history of previous work.

Inspect the casing by all means and see if the rotor magnets have been severely affected

by it, you dont want them breaking up cos you'll get the blame !!



I'd stop, tell the owner what you found, give him some options

and wait until he throws money at you before spending anymore time on it.

At least the old Viagra stators are easy to get at




Reg,



I think you´re spot on. I talked to the guys at "my" Honda / Yamaha shop and the chief mechanic agreed - probably something that has attached from the workbench to the flywheel (magnetics) some time, when the engine has been apart. The bolt fragment doesn´t really look like it could come from the bike and it´s clearly the outer end of a bolt.



The owner (who really doesn´t have a clue about his bikes) seems to remember that he had to replace the battery a couple of times in the past. Might very well have been charging problems - he has forgotten any details about when and where. The bike was used by the owner when he lived in Germany and was left sitting for some years before it was handed over to me to fix and get Swedish papers for it. The owner also knows nada about the bike´s previous history. He agreed about me putting it together with the new stator and will go on from there.



Sture
 
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