Alternator and brushes ( pics)

[Relax]

Standard, 2001, 115' km ( 71 ' miles)

I've been reading around and found that some advice check of brushes & cleaning alternator around now..   So, to get my peace , here we go


This is what I found when I took the alternator cover off.
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Seat, side covers were removedl, mid-cover loosen so i could push it away if i needed it.


3 bolt on the unit removed and by pushing and pulling i got it moved out.. ( narrow & tight, yess!)
By lifting  the rear of the alternator up, I got it out in front downwards.. hence losen the mid cover!

2  wired removed when I got to see them, no problem.



Out
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I took the pic to "document" where brackets and things are for installation later.


Drew a scratch line along the whole alternator to have mark for assembling later, had the long bolts out,  then pulled it apart by using a screwdriver and bend where the long bolts where removed.

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Where to solder if you need to replace brushes.
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According to the manual, brushes should be replaces if they were worn down to, or close to, the wear marks.
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Mine were, despite 70 000 miles ,,not even half down worn.



The engine without the alternator
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Alternator place.
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Now the tricky part  was on...installing!

By liften the rear end of the alternator some up and in,,,I could see that I would get space for pushing the front end in too.  Then I connected both wires!!! 
AND, when i focused and aimed the blades on the alternator into right places on the engine part,,and then push and pull a bit...it went in in some minutes.,,,not too hard!

After installation I fired up to check.
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Time for a ride and a cigar

[pancho]

Another good write up Relax,, you may not be a mechanic, but you sure are starting to resemble one!!! Good job.

[The emperor has no clothes]

Yes excellent write up. I`m going to save this for when it`s my turn.I have 45k, what`s the recomended mileage for checking the brushes?

[wiggydotcom]

Excellent write up, Relax. I feel like you've saved us from some pitfalls. And your excellent pics will help too.  

[old2soon]

Makes me want to run out and change the brushes NOW.  Oh wait-just changed out the entire altenator last year.  GOOD write up.  RIDE SAFE.

[Mallett]

Thanks for the post...what is the parts number for new brushes?

[Relax]

Thanks for the post...what is the parts number for new brushes?

31101-MN5-005

[Relax]

Due to a discussion, one more pic.




The Valk use two pieces of the brushes ..
Just for the fun of it, I put my knife where the wear mark is ,,

The pic also show the spring that comes with the brush...

[Blackduck]

For those that don't know but may have a go at changing the brushes. Before attempting to instal the rotor in the housing you need to pin the brushes in the housing.
Insert a piece of wire in the hole in tne brush holder, push the first brush in and push the wire through the hole in the brush then repeat for the second brush.
After the rotor is back in remove the wire. The hole can be clearly seen in the first pic of the dismantled alternator.
Cheers Steve

[Relax]

Murphy's law ??

Just weeks and 5000 km after I did this check of my alternator, I lost the charging on my bike on the road
 
I had no choice , but had to visit a work shop on the road..Fault: Break in windings.
An expencive experience !!

SO,,,a better advice than checking brushes and clean the alternator, is maybe to replace the complete alternator  when you get a good deal on a complete one? The ones you get "on the road" is at a high price!
Then both brushes, voltage regulator, windings are replaced....

[The emperor has no clothes]

Ouch! That sucks

[old2soon]

The broken windings of the lousy chinese wire is what took mine out and according to the owner of M A R S-it is what takes out a lot of the Honda alts. RIDE SAFE.

[Ricky-D]

The broken windings of the lousy chinese wire is what took mine out and according to the owner of M A R S-it is what takes out a lot of the Honda alts. RIDE SAFE.

That's why I think a rebuild from Ken would be the best insurance of that, to not happen again.

He's a upright guy (Ken), and I feel he really does his utmost best to give us a good, reliable product.

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[old2soon]

The broken windings of the lousy chinese wire is what took mine out and according to the owner of M A R S-it is what takes out a lot of the Honda alts. RIDE SAFE.

That's why I think a rebuild from Ken would be the best insurance of that, to not happen again.

He's a upright guy (Ken), and I feel he really does his utmost best to give us a good, reliable product.

***

     Since I changed it out with one of his rebuilts-on 4-27-2012 20750 miles ago it's still all good. And a brand new Yuasa battery with the rebuilt alt. I'd do business with him anytime.  RIDE SAFE.