Signal Generator Problem. Help?

[looshin]

So the other day I was riding when my bike started backfiring and died on me.

I took off the signal generator cover and found that the bolt holding the signal rotor had come loose. Problem is, it had broke off right at the crankshaft, so now the rest of the bolt is still screwed in.


I was thinking of getting some sort of bolt remover kit to try to get it out. And also getting a new signal generator assembly, this one looks pretty beat up with all the melted plastic.

Any suggestions?

Never done work like this before on a bike.

[Funderb]

use a small ez-out bit, they have good instructions that show you exactly what to do. when you replace the whole thing, and you'll need to, use blue threadlocker to keep it from happening again.
My sig generator failed before june, they are about 160 bucks new. still haven't gotten one yet.

[Dizzledan]

It's definetly not new, but I've got one if someone wants to mess around with it.
http://imgur.com/X5r3U

http://gstwins.com/gsboard/index.php?topic=60956.0

[looshin]

Got the bolt out! And put a new one in, bike runs but the signal pickups are clearly messed up and the rotor hits them.

Does anyone know if buying the signal generator assy 33110-44420 includes the pickups or should I be getting the igniter 32900-01D10?

http://www.powersportsplus.com/parts/search/Suzuki/Motorcycle/2000/GS500E/SIGNAL%20GENERATOR/parts.html

[edwardvdh]

holy crap! so my bike has been down for over a year after it died on my friend on the highway (backfired and never started back up). finally got to working on it and after going through pretty much everything else on the bike i opened the signal generator and found it was completely unscrewed! i had a little more luck than you looshin in that only the two screws holding the generator came out, not the bolt holding the rotor. all i had to do was screw em back in and it worked! seems a bit funny for it to come loose like that though. good luck with the fix!

edward

[Paulcet]

Got the bolt out! And put a new one in, bike runs but the signal pickups are clearly messed up and the rotor hits them.

Does anyone know if buying the signal generator assy 33110-44420 includes the pickups or should I be getting the igniter 32900-01D10?
http://www.powersportsplus.com/parts/search/Suzuki/Motorcycle/2000/GS500E/SIGNAL%20GENERATOR/parts.html

Yes, the assy includes the pickups.  No, don't get the igniter. It isn't likely to be faulty.

[bsheppar]

Hey looshin, what exactly did you use to get the broken bolt out? I have the same exact problem.

[looshin]

1. Went to Home Depot and got a screw extractor bit that would work on a M6 screw.
2. Centerpunch and drill a small hole (no more than half the diameter of the bolt)
3. Used the bit I bought and it came right out no problem.

[iclrag]

theres always the tap / die way to, but that's too much work, the bolt extractor is easier