'81 650 special 2 charging system

[chuck19836]

Ive got a '81 650 special 2 and full battery will only last 50 miles or so...rotor only ohm'ed at 1.5 ohms..replaced with one from Mikes XS new one ohm'ed at 5.6 ohms. now bike will not start. I checked the new rotor does have the ignition contact on outter slip ring also when are brushes wore out and need to be replaced

 

[650Skull]

There is a wear mark on them. They can b suspect when they are close to the mark. Also make sure the wire from the stater and also the Pic-up coil on the outside of the Stater has not been pinched when the cover has been put back on. The wires are routed close to the front sprocket, check and make sure they haven't been damaged there

 

[5twins]

New brushes are a little over 14mm long. The wear limit is half that, about 7mm, but as Skull said, you may want to replace them sooner, like at around 10mm long .....

 

[jetmechmarty]

Ive got a '81 650 special 2 and full battery will only last 50 miles or so...rotor only ohm'ed at 1.5 ohms..replaced with one from Mikes XS new one ohm'ed at 5.6 ohms. now bike will not start. I checked the new rotor does have the ignition contact on outter slip ring also when are brushes wore out and need to be replaced

I hope you didn’t throw the shorted rotor away. @Jim can rewind it to better than a new one. There have been documented aftermarket rotor failures right out of the box.

 

[chuck19836]

I hope you didn’t throw the shorted rotor away. @Jim can rewind it to better than a new one. There have been documented aftermarket rotor failures right out of the box.

no I did not I was wondering if that was possible

 

[Jim]

no I did not I was wondering if that was possible

MikesXS' rotor's are made in China. Take that for what it's worth. Yes, I can rewind the original provided it was properly removed and not bent to hell by other means.

http://www.xs650.com/threads/rewound-alternator-rotor.54276/

 

[chuck19836]

MikesXS' rotor's are made in China. Take that for what it's worth. Yes, I can rewind the original provided it was properly removed and not bent to hell by other means.

http://www.xs650.com/threads/rewound-alternator-rotor.54276/

Jim would you have a late style rotor then id send you the core removed with a 2 jaw gear puller

 

[Jim]

Jim would you have a late style rotor then id send you the core removed with a 2 jaw gear puller

I have exactly one core left that I can rebuild. If you want it, shoot me a PM and we'll go from there.

Everyone else hear that? I have no rebuildable cores left beyond this one. It'll be rewinds only from here on out... no more outright rotors unless/until I get some good cores.

If yours was removed with a 2 jaw puller, there's about even odds it's bent beyond being rebuildable. So yeah, you can send it to me, but there's no guarantee you'll get credit for a core.

 

[chuck19836]

how are you to pull them

 

[Jim]

how are you to pull them

As explained in my rewind thread and the shop manual... with a special puller. 'bout 20 bucks from MikesXS or Amazon, among other sources. I also have a loaner available... as explained in my rewind thread.

 

[chuck19836]

The other thing that I found is convert system to perm. mag. like other bikes and small engines whats your thoughts

 

[jetmechmarty]

The other thing that I found is convert system to perm. mag. like other bikes and small engines whats your thoughts

No. If you have a stock system with Jim’s rewind, it will run trouble free forever. Maybe brushes once every few years.

 

[Its been a long time]

The other thing that I found is convert system to perm. mag. like other bikes and small engines whats your thoughts

One thing I have learned from here is that with a modern rectifier and automotive regulator, a well looked after standard alternator system is hard to beat.

I fitted new brushes and modern bridge rectifier along with a generic automotive regulator. The whole set up cost me less than £25 to do. Of course, I checked out the rotor and stator windings first. They were fine.

 

[chuck19836]

what is the thread pitch for small screws that hold wires to stator my guess is like a 6-32 x 1/4" or 8-32 x 1/4" but probally metric

 

[jetmechmarty]

what is the thread pitch for small screws that hold wires to stator my guess is like a 6-32 x 1/4" or 8-32 x 1/4" but probally metric

Yes. Metric.

 

[5twins]

Yes, they are metric, an M4 x 8. The 4 that mount the brushes and brush holder are a little bit longer, M4 x 12. Don't mix them up. A screw that's too long will stick through too much and can contact and damage the rotor.