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TCI Replacement 2020

Discussion in 'The Garage' started by Team Junk, May 15, 2020.

  1. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    These magnets are quite a bit stronger than the stock ones so I don't think it will be a factor. At one point the pickup was at a greatly less than optimum position vs. the arc of the magnet and sparked like mad on the simulator .
     
    MaxPete and Jim like this.
  2. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

  3. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

  4. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Who you callin' a slug boy... :cautious:
    turbo_682_682_341_int_c1_c_c__1.jpg
     
    thuban, Paul Sutton, MaxPete and 2 others like this.
  5. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Uh Houston.... we might just have a problem here.... :cautious:

    So... I'm gonna run through the magnet installation, but first... here's a shot of the finished rotor next to a oem TCI rotor. See if you can spot the problem.


    a11.jpg
     
    Paul Sutton likes this.
  6. Superjet

    Superjet XS650 Guru Top Contributor

    Will the magnet transfer to the adjacent bolt and cause an early signal to fire? And then fire again at the magnet?
     
    Paul Sutton, Jim and gggGary like this.
  7. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Alrighty then.... the 1/4" end mill bits showed up today, so the first thing I did was drill into some scrap phenolic sheet to see how well the phenolic drills. It drills pretty good, but neither of my brand new end mills ran true. The hole on the left was the best at .258, so that's the bit I went with. Funny that... 2 end mills for 5 bucks from China... and I expected 'em to run true. :rolleyes:


    a5.jpg


    Anyway... centered up the rotor in the press and went just slightly deeper than the 1/16" thickness of the magnet. Reason for that is I wanted some JB Weld underneath the magnet as well as around it.


    a6.jpg
    a8.jpg


    The magnets are nice and polished so I sanded the side and bottom so the epoxy has some teeth to bite into. 400 grit did just fine for that. To find the "bottom" of the magnet, I tested the polarity against the TCI rotor. So I don't know if it's north or south, just that it's the same. I'll hunt up a compass to find out and add that info here shortly.


    a9.jpg


    And glued it in.


    a10.jpg


    I'll let it cure overnight and clean up the edges.... then on to some testing. Anyone spot the potential problem?
     
    Last edited: May 23, 2020 at 4:50 PM
  8. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    Ding ding ding.... give that man a ceegar. :smoke:

    I've rebuilt prolly 30-40 rotors now, so I knew the fastener pattern changed when they went to TCI... just never gave it much thought. Now I see why... the outer fasteners are running in the same orbit as the magnet. I've rebuilt this rotor with stainless screws, so I don't think it will be a problem. However, the originals were built with plain steel screws. When energized, the pickup will effectively see 5 "magnets." I'm ponderin' some fixes.... copper tape, replace the screws with stainless... we'll see after I energize it tomorrow.
     
    MaxPete, gggGary, GLJ and 1 other person like this.
  9. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    Hole is awfully close to the copper track . If need be a nylon screw will fix ghost signal.
     
    gggGary and Jim like this.
  10. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    Stainless should be somewhat less magnetic so should be ok. That little button magnet is powerful.
     
    MaxPete, gggGary and Jim like this.
  11. Superjet

    Superjet XS650 Guru Top Contributor

    Wonder how sensitive the TCI trigger is?
     
  12. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    More than sensitive enough to pick up the screws... the plain steel ones that is. The best fix will be to replace the outer screws with stainless when you mod the rotor... but that can be tricky. Based on my experience working with 'em, Yamaha or Hitachi... or whoever built 'em was kinda sloppy with the epoxy and sometimes slopped some on the screw threads. I haven't kept count, but I'd guess about every 10-15 screws and I'll wring off the head on one removing it.... stuck solid. Then ya gotta drill and re-tap the hole. And that means disassembly. I remember one rotor where all 7 screws broke. Figurin' labor... I made about a buck and a quarter an hour on that one. :rolleyes:
     
  13. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    Drill and tap 3 new holes in the center ring for a total of 6 like the TCI rotor and remove outers (screw driver, drill bit, small thermonuclear device what have you).
     
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  14. Paul Sutton

    Paul Sutton Buckhorns on XV1000SE Top Contributor

    Use brass screws???
    Some stainless grades are more magnetic than others - test to see what grade the screws should be???
    Mill the top off the screws to make them flat headed and then put a copper or aluminum disk over the top as a shield???
    Replace the screw with a magnet then offset the inductive pickup???
     
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  15. gggGary

    gggGary Stop that! XS650.com Supporter Top Contributor

    Remind me; why are we in this swa(m)p?
    Allen Millyard! Build a radial XS650!
    Um late model rotors aren't exactly "rare"?
    don't recess the magnet as far and raise the pickup? How much "room" is there twixt the rotor and frame?
     
    MaxPete, Jim, GLJ and 1 other person like this.
  16. Paul Sutton

    Paul Sutton Buckhorns on XV1000SE Top Contributor

    In reference to gggGary's comments above: On my previous SH I glued a 0.5mm thick magnet over the top of the old magnet. So clearly there is space for the magnet to be raised a little. The pickup could also be raised a little by inserting a washer or two under those mount screws.

    Must go, got to pee!
     
    MaxPete, thuban, Team Junk and 2 others like this.
  17. Jim

    Jim Beyond the edge, is the unknown. Here be Dragons XS650.com Supporter Top Contributor

    We're not gonna have any answers until we do some testing....but we have options.


    Untitled.png
     
    MaxPete, Paul Sutton, gggGary and 2 others like this.
  18. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    Box on left is the Virago box I've been using(I think the same size as the stock TCI box and Gonzo box on right).

    DSCN0002.JPG
     
    Last edited: May 23, 2020 at 12:21 PM
    MaxPete, gggGary and Jim like this.
  19. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    Is this insider trading. The day I posted this thread I ordered 2 boxes from the same place I got the first one. Price was roughly $10.00 a piece and they had 5.
    Now they are shipping in the middle of June and the price is $17.69. I suspect that more than a couple of people here are playing in this sandbox.
     
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  20. Team Junk

    Team Junk XS650 Junkie XS650.com Supporter Top Contributor

    They may think it's a Movement, and that's what it is
    The Alices's Restaurant anti-massacre movement!
     

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