SuzukiSavage.com - Alternator Rotor won’t budge

ThumperPaul

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Alternator Rotor won’t budge
08/05/24 at 11:52:05

What am I doing wrong?

I’ve loosened the main bolt hiding behind the rotor puller tool.

Screwed on the 50mm rotor puller. Start tightening the jab bolt assembly against the main bolt expecting to see the alternator rotor to move outward. I can’t put enough force on the jab bolt assembly to get it to move.

Can I put my air impact on it? Am I missing a step?

I had removed the 6 Allen head screws, but loosely reinstalled when I noticed they don’t seem to be holding the rotor back.

I’ve read Clymer and I’m still lost and unclear. This was much easier on the pit bikes I’ve worked on.

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1823 Houston, Texas Gender:	Re: Alternator Rotor won’t budge Reply #1 - 08/05/24 at 14:41:30 Got it off. 1) Remove the 6 Allen bolts to lighten the load and take baby steps. 2) Loosened the main nut further out. Clymer says a few turns. Try more like 6-8 turns. 3) Break out the air impact wrench. Now figure out how to get the stuck woodruff key out.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1823 Houston, Texas Gender:	Re: Alternator Rotor won’t budge Reply #2 - 08/05/24 at 14:45:00 Stuck woodruff key. Suggestions? Penetrating oil and what tool? I don’t want to damage anything (like the crankshaft, lol).
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JOG

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Re: Alternator Rotor won’t budge
Reply #3 - 08/05/24 at 15:40:43

Put a good penetrant on it. Walk away. Do it again. Take a hike. Come back, take a punch and drive down on the high end. You want to focus the shot on the high end, at the end. Once you get it rocking you can tap it out. Drive the outter end in. Hit the high end and slip something under it. Pry it out. It might be easier. That is for a stubborn one.

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1823 Houston, Texas Gender:	Re: Alternator Rotor won’t budge Reply #4 - 08/05/24 at 16:33:15 Thanks Graybeard. That's basically the plan I had. Sucker is stuck! Trying not to scratch and scar anything.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1823 Houston, Texas Gender:	Re: Alternator Rotor won’t budge Reply #5 - 08/05/24 at 17:42:19 Hey. There's a youtube for it that doesn't require any fancy tools. Still makes me nervous with a punch and a screwdriver near the crankshaft. There's a youtube for everything these days. https://youtu.be/BqAAIFhi-MA?si=9QMHJv44B5uf6RTi
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2784	Re: Alternator Rotor won’t budge Reply #6 - 08/05/24 at 18:56:47 I always used a punch. I assume my father taught me that when I was young. But there is more than one way to skin a cat. https://www.youtube.com/watch?v=XqV3gnBt5No
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Re: Alternator Rotor won’t budge
Reply #7 - 08/06/24 at 04:06:58

When using the puller - you have 2 choices. Some folks use the impact wrench - it works but I don't like putting that much stress on things. The other method is to tighten it up really tight by hand, then whack on the end of the puller screw with a hammer (Hit the end of the screw as squarely as you can or you will round off the end of the screw).

I use the diagonal cutter method to remove the key - sometimes it is just too tight to get the key started. I use a flat punch or dull chisel to get the keyway started when it is really tight. Drive with the punch parallel with the surface of the shaft.

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ThumperPaul

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Re: Alternator Rotor won’t budge
Reply #8 - 08/06/24 at 05:04:09

Thanks guys. I was hesitant to try the punch. The darn thing is stuck in there good and I was wondering…. Did I miss a step? Is there something obvious I’m not getting?

I felt more comfortable with the air impact on the main bolt. I didn’t want to risk de-magnetizing the rotor by striking anything with a hammer.

Now I’m thinking…if the alternator rotor was this much fun, the flywheel is gunna be twice as fun!

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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1823 Houston, Texas Gender:	Re: Alternator Rotor won’t budge Reply #9 - 08/06/24 at 06:41:56 Lookie what I got. Not even a nick or scratch! Thanks guys! All the tips and tricks were helpful. SuzukiSavage.com members Rock!
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4411 Honolulu	Re: Alternator Rotor won’t budge Reply #10 - 08/06/24 at 11:57:33 Congrats. I am a fan of the punch method. How did you get it out? Whatever you do, don’t file or sand on that key in an effort to make it easy to install or remove. It needs to be tight, just the way you found it.
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ThumperPaul

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Re: Alternator Rotor won’t budge
Reply #11 - 08/06/24 at 12:35:10

Thanks Mike. I used a punch on the inside edge (nearest the starter gear) and outer edge finally raised up. Then used a dull chisel to tap it up/out. Some penetrating oil overnight seemed to help too.

Nope - no sanding or nothing! Wiped off the excess oil and put it in a small plastic bag and let the rotor magnetic hold on to it for safe keeping.

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