fitting alternator cover

Finally getting around to finishing off the bike today after numerous
delays due to many issues both related and unrelated to the
bike...anyway...

I'm trying to get the alternator cover back on, but it just doesn't
want to go. The manual doesn't really say much to help. Are there any
special tricks or otherwise undocumented procedures that must be
followed? It seems to be obstructed by the gears for the starter
motor, but I can't see how/why this has become a problem since I never
touched them. Any ideas/assistance greatly appreciated!

Everything else is looking pretty good and this is about the only
thing standing between me and a running bike at the moment, so it's
really giving me the shits! I would have done it ages ago but for
excessive procrastination regarding the gasket, which is the only
reason it's still outstanding.

Damien
GPX250 -> CBR600 -> Shadow?

 

Okay, found the problem...the idler gear for the starter motor has
moved out of place, which is why the alternator cover wont line up
properly now...just have to work out how to get it back where it
should be now!


Damien
GPX250 -> CBR600 -> Shadow?

 

Are all the dowels in the right place?

Is the resistance from the magnet, rather than gears or the like?

Just make a gasket and put it back together.

All the best

Hammo

 

found the reason for the problem...there is a dowel that goes through
the idler gear which also fits into the alternator cover. This dowel
is also responsible for holding the idler gear in the correct position
against the rotation of the starter driven gear. However, when I
removed the alternator cover I did not realise this and in the absence
of the dowel the starter driven gear has been rotated and moved the
idler gear out of position...and since the starter driven gear only
rotates in one direction it is not possible to return the idler gear
to its correct position. The alternator cover wont go back on due to
the idler gear being out of position.

So...the question now becomes this: is it possible to do something
that will allow the starter driven gear to be turned counter-clockwise
(instead of its usual clockwise rotation) so that I can get the idler
gear back into the right position...or will I have to remove the
alternator rotor (to which the starter driven gear is attached) and
then install the idler gear and dowel and reinstall the starter driven
gear and alternator rotor and *then* get the cover back on?

I'm really hoping it can be done without having to remove the
alternator rotor as that requires a special tool and I'm really fed up
with spending money on tools & parts now, lol.

Damien
GPX250 -> CBR600 -> Shadow?

 

(normally called an idler shaft in this context, BTW. Dowels are
just those little ones which locate the covers but nothing turns on
them.)

Normally the whole thing will wriggle back together (hell, turn the
crank around until it does), but if not, pull the starter motor out,
put the idler gear in on its shaft, reinstall starter motor.

If I'm completely missing the point of this specific problem, email
me a photo (or post a URL) and I'll speculate wildly further!

Generally a threaded puller, right? Easy enough to make that
special tool anyway ... it's basically a bolt with the end cleaned
up.

-----sharks

 

Hmmm

A number of rotations won't allow it to go back into position? I'd keep the
pulling (oh er) of things as an ultimately last resort. The thought being
if it "moved" by itself, it should move back with minimal resistance. The
dowel may be able to slid from the cog and then allow repositing.

I'd go for simple things first, even it requires drawing a piccy to mull it
over rather than getting pissed off and breaking things. Often a decent
glob of grease will hold things in place and not cause dramas if not wiped
clean after putting all back together.

Have fun, and often how to do it will come to you in a dream. Think of 6
snakes and go from there.

Cheers

Hammo

 

Possible Answer:-
Put bike on centre stand, (or block it up with rear wheel off ground)
Remove spark plugs.
Put in mid gear. (trial & error)
Rotate rear wheel in reverse direction until idler lines up with
peg/pin.
Carefully relocate idler gear and replace the gasket and cover.

Failing that, just ask any Kiwi that lives near you to help.
A Kiwi can do it!
Flame suit on ! heheh

 

Thanks for the suggestions guys!

It's all sorted now, but in the end it was easier to remove the
starter motor then reinstall the idler gear and dowel before putting
the starter motor back. All good now though, thanks.


Damien
GPX250 -> CBR600 -> Shadow?

 

Bloody Great Hammer.

Theo

 

....and you are super too, Theo.

Hammo

 

Sometimes I wonder what you are on about Hammo. Other times I wonder what
you are on. Mostly I don't care.

Theo

 

whoosh!

 

X-No-archive: yes
Hamish Alker-Jones wrote in message ...

 

Seeing as you don't care...it was what you snipped.

Hammo

(Welcoming "THE VELVET HAMMER"!!!!!!)

 

Bloody idle dowel bludgers...

Postman Pat

 

Classic Postman Pat.

But in person.....sigh.

--
Conehead
"Every day I think about dying.
About disease, starvation, violence,
terrorism, war, and the end of the world.
It helps keep my mind off things."
McGough