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Message started by Chief Gunner on 09/26/10 at 17:28:59

Title: generator cover compatability problem / question
Post by Chief Gunner on 09/26/10 at 17:28:59

I'm installing a 96 engine in my 87 and ran into a compatability issue. I had to use the generator cover from the 87 because the one on the 96 was damaged. I swapped out the coil and wiring not a problem, but when I went to put the cover on I noticed a large difference. The gear right next to the rotor is thicker and has a longer shaft (insert bad joke here). I was able to use the gear and shaft from the 87 and it still engaged everything to the left perfectly but I also had to swap out the gear and shaft to the right to compensate.
It appears that everything is meshing up properly and the cover fits fine, just wanted to check with the more experienced guys here for any known issues. I can post picture tomorrow if needed.

Title: Re: generator cover compatability problem / questi
Post by verslagen1 on 09/26/10 at 17:39:58

So you swapped out the cover and all of the gears from the 87 to the 96?

This eliminates the torque limiter on the starter gear. What happens is on shutdown the piston will come up to TDC and stop. And the compressed gases will cause it to go backwards. This will engage the starter. If it's strong enough it can break the mounts for the starter. One fellow pm'd me regarding the opposite of what you're doing. putting the latter gears on a early bike. Had to machine the cover back about a half inch. Haven't heard back from him yet to know if it works.

So I think it'll work, but take the precaution of snubbing the rotation when you shutdown so it won't rotate backward. In other words, when you shut off, let the clutch out while in gear rather than let come to a stop by itself.

Title: Re: generator cover compatability problem / questi
Post by Chief Gunner on 09/26/10 at 17:48:38

So you are saying stall it out instead of shutting off with the clutch pulled in putting the stress on the crank and trans instead?? Or do both at the same time? Never had a problem stopping with the 87, but If they changed it out in later engines they must have known this to be an issue.
Didn't really haved a choice but to swap the cover had a nice hole from shipment, that and the ones on the 87 were polished up all nice a pretty.

Title: Re: generator cover compatability problem / questi
Post by verslagen1 on 09/26/10 at 18:00:05

Hit the kill button then let out the clutch before it comes to a stop by itself.

I hear the starter twang every so often.

Title: Re: generator cover compatability problem / questi
Post by Chief Gunner on 09/26/10 at 18:08:43

Sounds easy enough, thanks brother. Think I'll keep the extra starter just in case ;). Probably have some business for you with the old tensioner!!

Title: Re: generator cover compatability problem / questi
Post by verslagen1 on 09/26/10 at 19:17:25

There's also a circuit that'll kick in the decompressor on shut down.

And I bet you could hook a lever to the decompressor arm that'll let you activate it manually.

With the exhaust open, it'll spin down easy and not kick back.