expensive wheelie, magneto

[ripmonk]

hi there, so I'm brand new to this and just recently got an 05 gs500f. The second I got it I knew I would love it and I do, I just got a little over confident and tried to do a wheelie... anyway I broke the magneto cover, magneto (2) and magneto rotor (1). so I bought a new cover, mag and rotor and tried to install them, didnt get very far til I realised that the spinning shaft (4) was dinged so the rotor wont fit straight onto the shaft. I dont really want to have to replace the shaft due to draining the oil and splitting the case. just curious if you guys have any suggestions on how to fix this.

things I have thought of trying

-tighten up the rotor with the bolt and see if I can squeeze the rotor over the shaft
-sand down either the inside of the rotor or sand off the dings on the shaft   

p.s. how do I post pics? the numbers will make sense when I can get some pics up

[Janx101]

no idea on the magneto ..

but pics .. you can put them on your facebook or similar social site then post in a link .. you can put them on photobucket or similar free image hosting site and then put IMG links in.... its fairly simple... once you have got the pics somewhere that has the storage its all point and click stuff! 

[piresito]

hi there, so I'm brand new to this and just recently got an 05 gs500f. The second I got it I knew I would love it and I do, I just got a little over confident and tried to do a wheelie... anyway I broke the magneto cover, magneto (2) and magneto rotor (1). so I bought a new cover, mag and rotor and tried to install them, didnt get very far til I realised that the spinning shaft (4) was dinged so the rotor wont fit straight onto the shaft. I dont really want to have to replace the shaft due to draining the oil and splitting the case. just curious if you guys have any suggestions on how to fix this.

things I have thought of trying

-tighten up the rotor with the bolt and see if I can squeeze the rotor over the shaft
-sand down either the inside of the rotor or sand off the dings on the shaft   

p.s. how do I post pics? the numbers will make sense when I can get some pics up

Does that shaft rotates? If it is bent and you put the rotor in, wont it get an uneven rotation, producing all sorts of problems?

[Dizzledan]

If you bent the crankshaft, all hell will break loose if you end up getting everything back together. The clearance between stator and magneto is what generates a coinstant voltage for the charge. Not only will the bike not charge right, but you'll end up breaking the new hardware. At this point there's nothing left to loose so I vote that you try it, but you may end up puttIng in a new engine ($3-600) instead of a new crank, seals, etc.

[sledge]

Before you do anything you need to ensure the crank is not bent at the rotor seat. If it is bent vibration will be a bigger problem than a reduced airgap between the rotor and stator. To get any sort of accurate reading you need to use a a Dial test indicator (DTI)  and check the runout on the taper.....about 0.01-0.02mm max

If the shaft does run true you may be able to remove the high spots by lapping the tapers on the shaft and in the rotor together with very fine grinding paste until you get about 75% surface contact.

I suggest you get professional help with this issue.

[ripmonk]

thanks for the suggestions in the end I did get some professional advice and I checked the shaft runout and it was good so i grinded the shaft down til I could fit the rotor on, spun it by hand a few times and it is not crooked anymore. then strapped it all together and took her for a ride.

[mister]

Squid

[codajastal]

Squid

[sledge]

thanks for the suggestions in the end I did get some professional advice and I checked the shaft runout and it was good so i grinded the shaft down til I could fit the rotor on

You ground it?

So we can expect you back soon asking why the rotor keeps coming loose? 

[burnchassis]

What kind of wheelie destroys the magneto,and or crank???
there must be more to the story....
-CS

[Shepa]

What kind of wheelie destroys the magneto,and or crank
there must be more to the story....
-CS

Unsuccesfull I presume. 



Anyway... what if the new magneto turns out to be for some other model, and after you buy the correct one, it won't fit on the grinded shaft?

If you have to modify anything, always modify the expandable (and easier to find) part, in this case, the magneto, not the shaft.
But that's just me.

[Huff1371]

Squid

So the next time I'm having a hard time getting a CV Axle out of a car I'll just cut it off with a torch to a more manageable length. Then match that cut to the new one. Then all thats left is to weld it back together after it's installed. This is perfectly fine to do right?

[The Buddha]

What kind of wheelie destroys the magneto,and or crank???
there must be more to the story....
-CS

Well if you bend that cover a bit you will easily have the stator and rotor make contact, and if you're not paying attention you can turn that whole side of the motor into a tornadic mass of magnetic steel, lacquer, copper and oil.
Happened to se7enty7, and to others too.
Cool.
Buddha.

[burnchassis]

Bend it ? HOW? that's my question.
-CS