Generator cover

Lil' Irv · 06-03-2012, 03:25 PM

Rolled into a fuel stop today and thought I heard/felt a crunchy/scraping sound. After gassing up I checked everything over and couldn't find anything amiss. About 4 blocks later while sitting at a stop light I heard it again coming from the motor. I pulled to the side and while the bike was idling could hear crunchy noises coming from the left side. Put my hand on the generator cover and it felt like bad things were happening inside! I immediately knew what was probably going on in there.

So anyway, got the bike at home in the garage now and I'm trying to get the generator cover off to see the damage. I have removed the vent tube and all of the bolts around the perimeter. The only bolt I didn't remove is the one for the idler gear. I'm thinking the cover should come right off now but no go. It will rock back and forth and show as much as a 1mm gap on one side or the other but that's it. I've used the 14mm allen to turn the motor thinking that loose bolts etc may have the stator jammed in the flywheel but it turns smoothly. Everything that I've read here and in the manual suggests that you simply remove the bolts on the cover and pop it off.

What am I missing?

1stiski · 06-03-2012, 03:49 PM

That's it, just remove the bolts . You may have some parts in a jam so to say , if all the bolts are off ,you should be able to remove with ease .

Sadlsor · 06-03-2012, 05:08 PM

That baffled me too, at first.
What the heck is going on??!?!
There's a honkin' BIG magnet inside that cover, and that's why it doesn't pull off easily. Serious, BIG, honkin', STRONG magnet. Which is why you can "slide" it a little bit, and nudge it around, but it won't come off.
But it will.
Trust me.
It will.
Be strong!

(But, of course, DO be sure every last screw is removed from the perimeter. That's important, too.)

Lil' Irv · 06-03-2012, 05:26 PM

No doubt there's some bad shit going on under there. If the magnet is that strong there should be a puller for it! Seriously, at 250 lbs I'm no lightweight and if that's just a magnet holding it on maybe it's time to check in at the old folks home. Sounds like I'll just have to keep fiddling with it and see if it works loose. I'll keep you posted.

Boatman · 06-03-2012, 07:18 PM

Quote:

Originally Posted by Lil' Irv

No doubt there's some bad shit going on under there. If the magnet is that strong there should be a puller for it! Seriously, at 250 lbs I'm no lightweight and if that's just a magnet holding it on maybe it's time to check in at the old folks home. Sounds like I'll just have to keep fiddling with it and see if it works loose. I'll keep you posted.

I just had mine off a couple days ago... the magnet isn't that strong. After wiggleing it loose from the dowel pins, you can pull it off with one hand.

I'd give the starter button a quick nudge and then try the cover again. At this point you pretty much can't do much more damage than has already been done.

Lil' Irv · 06-06-2012, 04:30 PM

I was finally able to get back to this last night and with the use of a wood dowel in the vent connection to make it easier to keep some constant pressure on the cover while at the same time turning the engine with the 14mm allen wrench I was able to get the cover off. I found what I fully expected to find:

Stator is not beat up too bad but still a worthless lump of copper

So the good news, I guess, is that there is next to no debris strewn around. Now the question is what parts do I need to replace. Obviously the stator and the bolts. Not entirely sure about the flywheel. All the little dings from the bolts bouncing around won't hurt anything but I'm not so sure about the inlaid strip at the back of the inside of the flywheel. What is it and what is it there for? Balancing? Vibration damping? Can anyone here shed some light on it?

One thing I won't have to buy is a new gasket - I have one hanging on the wall that I ordered with the intention of checking these bolts this spring. Just hadn't gotten a round to it...

For the record it's a 2004 S model with 24k miles on the clock. This is the first trouble it's given me so I sure can't complain.

MortimerSickle · 06-06-2012, 04:40 PM

I have an '04 flywheel. It is the early one without the keyway, if that is what yours is.

In fact I probably have most of what you need.

v8toilet · 06-06-2012, 05:00 PM

Shit there goes another one.... Was there some weird weather phenomenon this winter that is causing this? I know it's a known issue but seems like a rash of them lately.

This one doesn't look as bad as some. Hope the OP gets off easy.

Mine is coming apart as soon as the parts get here so I can check it.

slackmeyer · 06-06-2012, 05:25 PM

Quote:

Originally Posted by v8toilet

Shit there goes another one.... Was there some weird weather phenomenon this winter that is causing this? I know it's a known issue but seems like a rash of them lately.

This one doesn't look as bad as some. Hope the OP gets off easy.

Mine is coming apart as soon as the parts get here so I can check it.

I think the more common problem is the bolts backing out and shredding the stator. Can't remember seeing one with all the bolts sheared off, but maybe I haven't been paying attention?

Irv: that flywheel's gotta go, I'm afraid. I think you'd stand a high chance of having one of the magnets below the sheet metal on the inside of the flywheel come loose and shred your nice new stator.

Lil' Irv · 06-06-2012, 05:37 PM

Quote:

Originally Posted by slackmeyer

Irv: that flywheel's gotta go, I'm afraid. I think you'd stand a high chance of having one of the magnets below the sheet metal on the inside of the flywheel come loose and shred your nice new stator.

I'd have a hard time putting that one back on. Even if it didn't cause a problem I'd always know it was in there and be sweating it. Better to have peace of mind even if it's expensive.

I am curious as to its purpose though.

Lil' Irv · 06-06-2012, 05:32 PM

Quote:

Originally Posted by MortimerSickle

I have an '04 flywheel. It is the early one without the keyway, if that is what yours is.

In fact I probably have most of what you need.

First I'll have to get the puller bolts and get the flywheel off. If it's without the keyway I'll be in touch. Thanks!

Lil' Irv · 06-06-2012, 07:00 PM

Quote:

Originally Posted by MortimerSickle

I have an '04 flywheel. It is the early one without the keyway, if that is what yours is.

In fact I probably have most of what you need.

Removed the rotor bolt and can see that mine does have the keyway. What other parts do you have?

sstewart · 06-06-2012, 07:24 PM

Look at my thread on this. Trust me, it could be way worse. Cheapcycleparts for the parts,I've done the research. Pm if you need info on the fix.

Lil' Irv · 06-06-2012, 08:02 PM

Ok, so now I have another question. Did the '04's not have the torque limiter that I keep reading about installed in them?

Mine is just one solid piece

From time to time I have heard the snapping sound when starting that I assumed was the torque limiter doing its thing. In fact on the fateful day it did it three times when I first started it and I remember thinking to myself that I better check into the updated version soon. Was the sound I was hearing really the flywheel bolt snapping?

MortimerSickle · 06-06-2012, 08:13 PM

Quote:

Originally Posted by Lil' Irv

Ok, so now I have another question. Did the '04's not have the torque limiter that I keep reading about installed in them?
...

No torque limiter.

PM sent on the other stuff.

06-03-2012, 03:25 PM	#1
Lil' Irv ^OP Adventurer Joined: Jun 2004 Location: Chaska, MN Oddometer: 209	Generator cover Rolled into a fuel stop today and thought I heard/felt a crunchy/scraping sound. After gassing up I checked everything over and couldn't find anything amiss. About 4 blocks later while sitting at a stop light I heard it again coming from the motor. I pulled to the side and while the bike was idling could hear crunchy noises coming from the left side. Put my hand on the generator cover and it felt like bad things were happening inside! I immediately knew what was probably going on in there. So anyway, got the bike at home in the garage now and I'm trying to get the generator cover off to see the damage. I have removed the vent tube and all of the bolts around the perimeter. The only bolt I didn't remove is the one for the idler gear. I'm thinking the cover should come right off now but no go. It will rock back and forth and show as much as a 1mm gap on one side or the other but that's it. I've used the 14mm allen to turn the motor thinking that loose bolts etc may have the stator jammed in the flywheel but it turns smoothly. Everything that I've read here and in the manual suggests that you simply remove the bolts on the cover and pop it off. What am I missing? __________________ "Life is either a daring adventure, or nothing." -- Helen Keller Stranger 315 '04 KTM 950 Adventure S '04 BMW R1150RT

06-03-2012, 03:49 PM	#2
1stiski Ride that nasty thing Joined: Oct 2003 Location: Elizabethville, PA Oddometer: 1,425	That's it, just remove the bolts . You may have some parts in a jam so to say , if all the bolts are off ,you should be able to remove with ease . __________________ "04" 950 Adventure S 34,000+ miles Smokin Hole Rally 1,2,3,4,5,6...upcoming 7 Cromag 05, 08. "The Grim Brothers" Where's my 690 rally replica

06-03-2012, 05:08 PM	#3
Sadlsor Studly Adventurer Joined: Oct 2003 Location: Magic City in the Heart of Dixie Oddometer: 687	That baffled me too, at first. What the heck is going on??!?! There's a honkin' BIG magnet inside that cover, and that's why it doesn't pull off easily. Serious, BIG, honkin', STRONG magnet. Which is why you can "slide" it a little bit, and nudge it around, but it won't come off. But it will. Trust me. It will. Be strong! (But, of course, DO be sure every last screw is removed from the perimeter. That's important, too.) __________________ You must be the change you wish to see in this world.

06-03-2012, 05:26 PM	#4
Lil' Irv ^OP Adventurer Joined: Jun 2004 Location: Chaska, MN Oddometer: 209	No doubt there's some bad shit going on under there. If the magnet is that strong there should be a puller for it! Seriously, at 250 lbs I'm no lightweight and if that's just a magnet holding it on maybe it's time to check in at the old folks home. Sounds like I'll just have to keep fiddling with it and see if it works loose. I'll keep you posted. __________________ "Life is either a daring adventure, or nothing." -- Helen Keller Stranger 315 '04 KTM 950 Adventure S '04 BMW R1150RT

06-06-2012, 04:30 PM	#6
Lil' Irv ^OP Adventurer Joined: Jun 2004 Location: Chaska, MN Oddometer: 209	I was finally able to get back to this last night and with the use of a wood dowel in the vent connection to make it easier to keep some constant pressure on the cover while at the same time turning the engine with the 14mm allen wrench I was able to get the cover off. I found what I fully expected to find: Stator is not beat up too bad but still a worthless lump of copper So the good news, I guess, is that there is next to no debris strewn around. Now the question is what parts do I need to replace. Obviously the stator and the bolts. Not entirely sure about the flywheel. All the little dings from the bolts bouncing around won't hurt anything but I'm not so sure about the inlaid strip at the back of the inside of the flywheel. What is it and what is it there for? Balancing? Vibration damping? Can anyone here shed some light on it? One thing I won't have to buy is a new gasket - I have one hanging on the wall that I ordered with the intention of checking these bolts this spring. Just hadn't gotten a round to it... For the record it's a 2004 S model with 24k miles on the clock. This is the first trouble it's given me so I sure can't complain. __________________ "Life is either a daring adventure, or nothing." -- Helen Keller Stranger 315 '04 KTM 950 Adventure S '04 BMW R1150RT

06-06-2012, 04:40 PM	#7
MortimerSickle Semi-Adventurer Joined: Dec 2005 Location: Rainville, Orygun, where moss is a road hazard. Oddometer: 9,822	I have an '04 flywheel. It is the early one without the keyway, if that is what yours is. In fact I probably have most of what you need. __________________ I miss round headlights. "When I was a young man, I liked to race my horse...." - G.H.W.S. 1878-1962

06-06-2012, 05:00 PM	#8
v8toilet Nothing to see here. Joined: Jul 2005 Location: Northwest U.S. Oddometer: 1,563	Shit there goes another one.... Was there some weird weather phenomenon this winter that is causing this? I know it's a known issue but seems like a rash of them lately. This one doesn't look as bad as some. Hope the OP gets off easy. Mine is coming apart as soon as the parts get here so I can check it.

06-06-2012, 07:24 PM	#13
sstewart Studly Adventurer Joined: Nov 2009 Location: Boaz,Alabama Oddometer: 822	Stator Look at my thread on this. Trust me, it could be way worse. Cheapcycleparts for the parts,I've done the research. Pm if you need info on the fix.

06-06-2012, 08:02 PM	#14
Lil' Irv ^OP Adventurer Joined: Jun 2004 Location: Chaska, MN Oddometer: 209	Ok, so now I have another question. Did the '04's not have the torque limiter that I keep reading about installed in them? Mine is just one solid piece From time to time I have heard the snapping sound when starting that I assumed was the torque limiter doing its thing. In fact on the fateful day it did it three times when I first started it and I remember thinking to myself that I better check into the updated version soon. Was the sound I was hearing really the flywheel bolt snapping? __________________ "Life is either a daring adventure, or nothing." -- Helen Keller Stranger 315 '04 KTM 950 Adventure S '04 BMW R1150RT

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