Generator replacement

[GeeBee]

Hi, just new here and looking for help/advice if anyone else has had a similar issue - sorry the post is a bit long!

Few weeks ago my K5's starter motor gear lost a tooth which caused the generator flywheel (hope I'm using the right terms) to lose a tooth which lunched the stator and the generator casing around it. I found used replacement parts but when fitted onto the crankshaft the flywheel goes all the way back onto the engine casing and can't turn. Tried the knackered parts and they fit fine and move freely, but as soon as the replacement parts are torqued up to around 90-100nM they won't move. It's like the tapered part of the cover is microscopically too big for the crank, so sits further along it, causing the flywheel to foul.
I've tried different combinations of old and replacement parts and even bought a different generator assembly, all with the same result.

I did find a previous post regarding the stator bolt possibly being a stretch bolt (or just stretching), but I can't get my head around how a new bolt would hold the flywheel out from the engine, but I'm ordering a new one anyway. I know the crankshaft changed between the K5 and K6/7, but it doesn't look like that would affect the generator as those parts didn't change.

I am literally tearing out what's left of my hair! If I thought a new cover( £450 thank you very much) would solve it, I would probably think about it, but I'm worried it wouldn't fit as well.

Any thoughts?

[seth]

Go look at the parts microphiche on Robinson's foundry page .
And look at the Suzuki workshop manual and updates in the download section here .
It sounds like something is missing a spacer or washer as from memory all the parts are the same across all years.
the bolt problem was only on some k5's and the replacement bolts are fine .

[GeeBee]

Thanks, but been through Fowlers, Robinsons, my local dealer and had a bike mechanic look at it too - we're all scratching our heads having spent hours now online and on the bike. Nothing has changed, nothing is missing and the replacement parts I have here look right. If the crank was worn, the old parts wouldn't fit either.

Only thing I can think of is that the replacements are for another bike with similar crank etc. It may come to the point where I have no option but to buy a new part to see if that fits. Will persevere though and maybe someone, like yourself can spark a wee light on it.

Regards, GeeBee

[grog]

Mate, have you measured inside of old against new? To me only, sounds like new one just going up taper too far, wrong size. Nothing else to go wrong.   

[GeeBee]

That seems to be what's wrong, but I don't know why. Part seems to be identical (just tried a second one) but sits further along the crank (like, less than1mm) which is enough to make the flywheel foul on the casing. It's as if it's a part for another model, but checked the schematics at Fowlers and Robinsons and there's been no changes until K6 model.
Just not sure what to do now - was hoping that someone else here had encountered a similar issue. G

[Eric GSX1400K3]

Is the flywheel you bought been machined or lightened? Pretty sure they can only go on one way.  Have you checked that in the process of shearing off the tooth that the crank hasn't moved laterally?  Maybe you've mushed the endfloat washer on the crank so it's now sitting too far off centre. 

How did you manage to break that anyway? There must have been an issue to cause the starter motor and flywheel  gear mesh to not longer want to talk to each other.

[Snapey]

It can only be the size of the taper. The one you're trying to fit might have spun on the crank and the previous owned cleaned it up before selling it or it's not from a GSX1400.

[GeeBee]

Thanks Snapey & Eric (and others),
The taper on my crank looks unworn, as do the tapers on the replacement generators - although the margin is  so small it would be difficult to tell.
So we're coming to the conclusion that the replacements aren't from 1400s, K5s or otherwise; which is unfortunate as used ones are like rocking horse poo.
So will just have to keep looking and maybe buy a new one from Robinsons if one doesn't turn up.
Regards, Glenn

[Eric GSX1400K3]

What about the taper on the 2nd hand flywheel you bought ? Does it look like this has been newly machined ?

That's the only thing that would change  the final position of the flywheel.

[Hooli]

So will just have to keep looking and maybe buy a new one from Robinsons if one doesn't turn up.

You might be able to get the taper sleeved by a decent engineering place, not sure if it'd be cheaper than a new part or not though. I'd suggest somewhere like http://www.seager-engineering.com/ who did engine work on my Bonnie to an excellent standard.

[grog]

My thoughts also Hooli. Get exact matched to original.

[GeeBee]

Thanks, I'll look into that as I have both original and replacement here that they could take measurements from. It's a really fine amount so I'll measure them before asking. It's beginning to look a lot like new parts though.