Alternator Problem: Bigger than expected

[2E]

Well the title says it all.. Today has NOT been my day at all.. i am actually starting to think the man upstairs hates me... :shooter

Firstly, no parcels today:(

Oh well, the bikes getting fixed i thought..Finally im getting it all sorted:reading


Well:

Problem #1: I deliver a box containing the stator, a manual, gasket, and clutch cable to Swiftys the morning.

At around 3 oclock they ring me telling me the box is empty.. after a small argument i find the box is the wrong one, and contains my brothers warhammer models instead.:shooter

Problem #2: after delivering the stator we get the clutch cable given back, its the wrong one (G7-G8 model rather than G4) oh well.. i didnt pay much for it.. anyone want it??

Problem #3: The alternator is fubared.. and i mean.. FUBARED!!!:reading

The winding has eaten itself and the alternator around it.. when they opened the casing they found themselves covered with filings and broken pieces of metal, and a old worn stator sitting at the bottom of the casing.. it had actually broke the back of the casing...:shooter


Pics:


http://img.photobucket.com/albums/v285/essexbikers/DSCF0566.jpg


Nice Worn Stator as you can see..

Now check the back out...



http://img.photobucket.com/albums/v285/essexbikers/DSCF0565.jpg


That big block of metal is the back of the alternator rotor, which had completely broken off..:shooter


Conclusion:

Need to source a new rotor & cover for the bike in which to put the new stator.. for now, the bike can only be run at daytime (lights drain battery severely) and im going to have to take the battery out and charge it all the time until I get these new parts :(

[kasandrich]

I have a selection of knackered old batteries, if you charged them up and mounted them in your panniers and topbox, you could run a fair wile on total loss setup:rockon

Sorry to here of your troubles 2E

[DoodleBug]

There must be so many of those bikes in breakers yards, just about every DR used them a few years ago!

[bikermad]

sorry 2 hear about ya bike fella, gd luck with everything

[TALLTONE]

Thats the trouble with old bikes, when do you draw the line and say , im not spending anymore money on this poxxy bike. I had it years ago with an old ts185 which went like stink but was a barsturd to start even when hot. It became a challenge but in the end I realized I was waisting my money and eventually, lost my rag with it and swapped it for a dt175 and 100quid. Im not suggesting you are waisting your money, Couldnt you chop it in as down payment on something else. I remember you talking about getting another bike.

[RaceMeNSee]

Thats the trouble with old bikes, when do you draw the line and say , im not spending anymore money on this poxxy bike. I had it years ago with an old ts185 which went like stink but was a barsturd to start even when hot. It became a challenge but in the end I realized I was waisting my money and eventually, lost my rag with it and swapped it for a dt175 and 100quid. Im not suggesting you are waisting your money, Couldnt you chop it in as down payment on something else. I remember you talking about getting another bike.


EXACTLY the same as my ZXR400...i loved it to bits - and at the time it was the fastest out of my mates bikes.......bu every single month....SOMETHING would go wrong with it! after having spent well over what i had origanally paid for the bike - i gave up, sold it and got my G ninja! I fixed it one last time, sold it privately and got another bike! perhaps you should do this?? Get it fixed - like your planning ot, bubt then seriously commit to selling it and find something else that you really like - but wont slowley destroy its self!

[STEALTH52]

I've tried suggesting this a few times but you know Tooey...Probably wont listen, I'd get seriously ****ed off off if I had a bike where I was constantly working on it all the time..

[Gixxer-TeZ]

I'd get seriously ****ed off off if I had a bike where I was constantly working on it all the time..



LOL @ John. You've spent more time and money adding mods to yours than 2E has repairing his.


:grin1

[STEALTH52]

LOL @ John. You've spent more time and money adding mods to yours than 2E has repairing his.


:grin1

Doubt it mate, Wouldn't say it's taken me 6 months :grin2

the new Mods will take a while though;)

Watch this space...

[two]

thats really really really not good news

you need to think about the bigger picture mate, its not just the Stator
the oil has/had a silver tint to it ?
metal filing will be in you oil.. which means they are going to pumped around your engine and gearbox
worse case, these filings in your oil will make there way to your big/little end bearings and then the engine will start knocking and may even throw a rod in time
this will means a rebuild or the easier (and cheaper) option is replacement engine from a breakers (although there is always a risk from a breakers of buying an engine that is just as broken... but most will give a short warranty)

hopefully your'll be lucky and all will be ok.. (sadly, we know that is not the 2E way)

was the oil drained from the bike when the engine casing was removed did anyone comment on the colour or stick a magnet into the oil..? or was the bike just leant over to save changing the oil..?
think about changing the oil and filter if you haven't already, in an attempt to at least get some off the filings out of the oil flow
using engine flush on an older engine is always risky... and normally results in oil leaking from gaskets in my experience

without a complete engine strip down, clean and rebuild your going to be playing a waiting game before the filings cause some damage
(you maybe lucky and no other damage will be caused... but its a gamble)

a 2nd hand engine can be had for about £100 for a GT.. (but unless it is local, your looking at another £50 postage)
then you've got to swap the engines (not a huge job to be honest...but you can bet on an older bike the odd nut or bolt is going to give you trouble and delay the process a couple of hours longer than is should take)
if your not swapping it yourself, it just wouldn't be worth paying someone to do it imo

bearing the above in mind, i'd serious give talltones advise some thought..? i know its not what you want to hear..but...
maybe fix the stator, make the bike marketable and sell it on and put the money toward something else, cut your losses
with you wanting to ride overseas i'd give something like the zzr600 serious consideration
(and if you wanted something different later, streetfighter it... although don't rule out zx6r f,g,j / jelly mould cbr)

[Webby]

Or buy one of these. Cheap as heck, low mileage and they are even Toeey proof in virtually every respect. I've had 3 and a 900 now and each has been thrashed soundly and still managed a commute to London and back daily along with the odd trip further afield. As the guy says, touring europe with one is not a problem. They are so basic they are a doddle to service.

Loads of parts available and this one comes with quality luggage.

http://cgi.ebay.co.uk/1992-Yamaha-600-Diversion-with-fairing-lower-panniers_W0QQitemZ290218291025QQihZ019QQcategoryZ9 809QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

[DoGbOt]

Yew,... a yamaha dullversion, well having ridden one of these & the fact that they are marketed in the same pidgeon hole as a Suzuki bandit, you'd get much more bike for your money with a faired bandit! plus they are bullet proof i swear by them & i'm gutted i just sold one so cheaply on ebay as i would have given it to tooey to ride round on........ just cos i know he wouldn't have been able to say no to having it, :laugh1

[DoodleBug]

http://cgi.ebay.co.uk/GT550-Engine-Bottom-End-For-Spares-GT-550_W0QQitemZ220216451764QQihZ012QQcategoryZ10464Q QssPageNameZWDVWQQrdZ1QQcmdZViewItem

http://cgi.ebay.co.uk/SUZUKI-GT550-ENGINE-MOTOR-CRANK_W0QQitemZ320233527406QQihZ011QQcategoryZ1053 4QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

http://cgi.ebay.co.uk/SUZUKI-GT550-RIGHT-SIDE-CASING_W0QQitemZ320233532033QQihZ011QQcategoryZ105 34QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

http://www.lm-spares.co.uk/acatalog/Kawasaki_Alternator_Windings.html

http://tuks.co.uk/default.aspx

might have the parts you need

[2E]

thanks for the links doodle but the second two are for Suzuki GT550, not kawasaki ;)

Emailing that Tuks bloke though, see if i can get a better price, been offered the parts i need for 33 quid all in all.. so not too bad.:grin2

[DoodleBug]

You arent going to do better than that, fix it and sell it. They seem to be going for about £500 atm.