Need Help W/ Alternator Rotor Bolt Removal - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 10 (permalink) Old 04-05-2012, 10:02 PM Thread Starter
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Need Help W/ Alternator Rotor Bolt Removal

Hi,

I need some help.

I am in the process of putting the bike back together after replacing the stator. As advised, I ordered crankshaft dampers to do some PM while I had everything apart. I have read everything I could find on removing the alt rotor bolt. I put a non-copper penny between the gears and have gone through ( cut them in half) two of them trying to get the rotor bolt to budge. I have the 18mm X 1.5mm X 60mm bolt on hand to remove the rotor if I can get to that point by removing the rotor bolt.

Any recommendations for loosening the rotor bolt?

Thanks

MAG659 - Mark George
Chagrin Falls, OH
1986 VN 750 - "Old Goat"
24,000 miles
Lubed Splines
MFB (Deka- AGM)
NKG - Iridiums
Plexistar II
Relocated R/R
Avon Venoms - wider
F-110/90
R-170/80
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post #2 of 10 (permalink) Old 04-05-2012, 10:04 PM
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said bolt is revers thread, meaning righty loosy lefty tighty.. try it the other way
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post #3 of 10 (permalink) Old 04-05-2012, 10:16 PM Thread Starter
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Do I have it backwards? I thought the rotor bolt was normal threads and the balancer bolt was left handed threads. Here is what I copied from one of Lance's posts?

• Make sure you remove the balancer gear bolt first. "left hand threads"
• Just shimmy a penny between the gears to hold them in place.
• First loosening the balancer bolt (clockwise) and then the rotor bolt (counterclockwise).
• Make sure you line up the marks on the rotor and gear, use blue thread locker on balancer bolt.

So is the rotor bolt turn CCW (rh threads) to remove or is it the balancer bolt?

MAG659 - Mark George
Chagrin Falls, OH
1986 VN 750 - "Old Goat"
24,000 miles
Lubed Splines
MFB (Deka- AGM)
NKG - Iridiums
Plexistar II
Relocated R/R
Avon Venoms - wider
F-110/90
R-170/80
K&N Air Filters
mag659 is offline  
 
post #4 of 10 (permalink) Old 04-05-2012, 10:40 PM Thread Starter
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Confirmed, balancer bolt is LH (CW to loosen). Just broke my third penny trying to get the rotor bolt to budge (CCW)...................

MAG659 - Mark George
Chagrin Falls, OH
1986 VN 750 - "Old Goat"
24,000 miles
Lubed Splines
MFB (Deka- AGM)
NKG - Iridiums
Plexistar II
Relocated R/R
Avon Venoms - wider
F-110/90
R-170/80
K&N Air Filters
mag659 is offline  
post #5 of 10 (permalink) Old 04-05-2012, 10:50 PM
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glad you got it figured out
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post #6 of 10 (permalink) Old 04-05-2012, 10:54 PM Thread Starter
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Any ideas for losening the rotor bolt? Is it safe to use something other than a penny between the gears? I think I read where a few people used a washer.........

MAG659 - Mark George
Chagrin Falls, OH
1986 VN 750 - "Old Goat"
24,000 miles
Lubed Splines
MFB (Deka- AGM)
NKG - Iridiums
Plexistar II
Relocated R/R
Avon Venoms - wider
F-110/90
R-170/80
K&N Air Filters
mag659 is offline  
post #7 of 10 (permalink) Old 04-05-2012, 11:51 PM
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washer, screw driver.. anything flat.. just be gental
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post #8 of 10 (permalink) Old 04-06-2012, 01:21 AM
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You may need an inpack wrench.

02 honda sabre 1100
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post #9 of 10 (permalink) Old 04-06-2012, 03:44 AM
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I just had a similar fight with the primary gear bolt of a Honda V65.

Don't use a penny between the gears. It works if the bolt is not jammed, but only puts a huge stress on the bearings if the bolt is stuck. Instead, use a piece of mild flat steel bar as far as possible from where the teeth of the two gears make contact. Not too far - you want it to still lock in place when you apply torque to the bolt.

I had to extend the handle of my wrench with a 3 foot piece of pipe before i could break the bolt free.
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post #10 of 10 (permalink) Old 04-29-2012, 12:15 PM Thread Starter
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Thanks for the Help

After breaking a strap wrench, and then finding out the cost for a KAW fly wheel holder was $250, I decided to use a chain wrench and a rag for protection. Finally got the bolt off and it was worth it since one of the dampers had a cracked collar. Now it is time to start putting it back together!

MAG659 - Mark George
Chagrin Falls, OH
1986 VN 750 - "Old Goat"
24,000 miles
Lubed Splines
MFB (Deka- AGM)
NKG - Iridiums
Plexistar II
Relocated R/R
Avon Venoms - wider
F-110/90
R-170/80
K&N Air Filters
mag659 is offline  
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