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But how do you remove the stator?
- Thread starter bankerbiker
- Start date
@bankerbiker , I moved the conversation over here from the oil seal thread. Works better here.
I rewind rotors. What year bike and does it have the factory TCI (ignition system)?
https://www.xs650.com/threads/rewound-alternator-rotor.54276/
I rewind rotors. What year bike and does it have the factory TCI (ignition system)?
https://www.xs650.com/threads/rewound-alternator-rotor.54276/
bankerbiker
XS650 Enthusiast
It is a 1983 XS650 Heritage Special, Canadian model (not sure how different it might be from the US version - maybe not at all). As far as I know, it has the factory TCI (is there a way to confirm that?).
The information contained in the threads is fantastic, and your offer to rewind the rotor is extremely tempting for a lot of reasons. Being in Canada is a little problem as the cost goes up due to shipping and duties. Technically, I think it could slips under the duties cost (there is supposed to be a trade agreement covering this, but trade agreements are a taboo subject right now), but you never know what happens when it crosses the border. Canada Revenue Agency always wants its share. I am going to make some enquiries locally, but if those enquiries don't pan out, I'll be coming back your way Jim. You have some great endorsements.
I am about to send my other XS650 (an '81 that kinda fell into my lap) to the mechanic for tires, fork seals and a safety certificate, which would put it back on the road. So I can take some time with getting the '83 fixed up and running again. I only got to put 400 kms on it before the leak and charging problem hit.
Thank you to all who have chimed in with suggestions for me. This site, as I had said before, is fantastic and any 650 owner should be a member of the site. It is filled with invaluable information.
Jim, I'll keep you posted on my success with a rotor search.
I've prolly sent upwards of 50 rotors to Canada.... or should I say to an American address on the border. Got an American friend just south of the border?
We loosely refer to it here as the Canadian mafia....
We loosely refer to it here as the Canadian mafia....
Whatever you do, don't buy one of the **new** Chinese rotors... unless you plan to buy 'em in batches of 10 and carry the rotor puller along for the ride.
Yeah.... they're that bad.
**If it's brand new, it's Chinese. No one else makes 'em.**
Yeah.... they're that bad.
**If it's brand new, it's Chinese. No one else makes 'em.**
bankerbiker
XS650 Enthusiast
I'm actually right on the border with the US. My Step-mom was Canadian born but a US citizen and lived in Michigan. I still have a step-sister and "cousins" in Michigan so yes, that is a definite alternative. I ordered scooter parts from Scooterworks in Chicago and would pick them up at an address in Michigan and bring them back across to Canada (all declared at the border of course!). I could do that again although my trips to the US have been curtailed for the last couple of years.I've prolly sent upwards of 50 rotors to Canada.... or should I say to an American address on the border. Got an American friend just south of the border?
We loosely refer to it here as the Canadian mafia....
My bike is the '83 Heritage Special. What issues do you see about working on the rotor? Would it help if I sent you any pictures, and specially of what?
Only two issues to look for:
Make sure to use a puller designed for it. A 2,3 or 4 jaw puller stands a good chance of bending it. All the (4 or 5) cores I've rejected was because the wrong puller bent the hell out of 'em.
Make sure there's a part # molded into the edge of the ring plate. If there's no part #, it's a Chinese forgery.
bankerbiker
XS650 Enthusiast
You're in luck, I just got a TCI rotor core back in the mail today. I'll get started rewinding it. If it turns out you don't need it, no worries, someone else will grab it.
Bob Wegman
XS650 Addict
bankerbiker
XS650 Enthusiast
Thanks Bob. However Rochester is too far away, and it would be easier for me to use Michigan since I am right next door.
But I greatly appreciate your willingness to help out in that way. Just another example of the great people on this site.
bankerbiker
XS650 Enthusiast
Wow, amazing news. it is said timing is everything. I hope to better check out and confirm that the rotor needs replacing by Friday once I get the puller. I'll keep you informed.
I was speaking with the previous owner of the bike today asking if he had any spare rotors lying around since he owned three XS650s at one time . No luck. He was a little surprised that the rotor was not working with so few kms on the bike, but agreed it could be the issue. He encouraged me to look for any broken wires or bad connections before writing it off though (which is my plan).
I may yet need to visit my step-cousin in Michigan.
bankerbiker
XS650 Enthusiast
bankerbiker
XS650 Enthusiast
My friend John was back in town today and came over to check on my progress. While we are waiting for the rotor puller and new oil seals to arrive (tracking tells me they are "on the move" which means they could arrive tomorrow, but maybe not), we took a good look at two of the potential leaking oil seals - the clutch pushrod and the countershaft. Since the area is already dirty here from the bike chain, it was hard to be certain if the seals were leaking. However, the countershaft seal was soft and came off very easily. The clutch pushrod seal was slightly more work, but in each case, it seemed that the seals were not doing their job. So now we have both those areas ready for the new seals. When we can get the rotor off, we will inspect that seal but frankly will simply replace it anyway since if two seals are likely leaking, this third one may as well be replaced too. That will also allow me do a thorough inspection of the rotor. We tested the stator and rotor again with John's multimeter, and got similar low readings for resistance in the rotor.
Having gone as far as we could on the '83, we did another check on the '81 in anticipation of taking it to the mechanic for tires, fork seals, and the safety certificate to get it on the road. We discovered a leak in the fuel line (bad clamp) and fixed a wobbly side stand to ensure it retracts properly. Once the tires and seals are done, we are confident it should pass the safety. Now to get time from the mechanic.
So a fairly successful day, with hoping my parts arrive tomorrow.
Having gone as far as we could on the '83, we did another check on the '81 in anticipation of taking it to the mechanic for tires, fork seals, and the safety certificate to get it on the road. We discovered a leak in the fuel line (bad clamp) and fixed a wobbly side stand to ensure it retracts properly. Once the tires and seals are done, we are confident it should pass the safety. Now to get time from the mechanic.
So a fairly successful day, with hoping my parts arrive tomorrow.
Just my 2 cents here, but if you are ordering a new clutch pushrod seal, order two. It is not uncommon to damage the first one on installation. Also, since you have two XS's now, it doesn't hurt to have a spare on hand. Cheap insurance if something goes wrong on the install so you don't have to wait another week for a new one.
Bob Wegman
XS650 Addict
Another thought, How about checking the rotor on your other bike and see if the readings are the same?
bankerbiker
XS650 Enthusiast
Great advice willis, thanks. Unfortunately, the stuff is arriving today so too late to order two. I will be extra careful with all of the seals.
bankerbiker
XS650 Enthusiast
More sound advice. Thanks. I should have done that when I had the cover off for painting. This bike has started easily every time (the previous owner had been riding it annually so it had not been sitting like the '83) and my trickle charger takes no time to get it to full charge again and indicates a good battery. However, testing the stator could tell me if I am getting wonky readings from the multimeter.
bankerbiker
XS650 Enthusiast
My parts order was delivered today. My friend John came over and we replaced two of the three oil seals that I plan on replacing (clutch pushrod and countershaft). We also pulled the rotor using the Yamaha puller (had to use the impact wrench but came off fairly easily). Looks like the crankshaft oil seal might have been leaking a little. However, we are having a harder time getting that one out as it turns out it must have been replaced before, because the seal is in backwards. We ran out of time so that will be my project tomorrow.
Tested the rotor again - same reading (0.6) as before. So rotor must be toast. Looking at the rotor, it is basically completely sealed. You cannot see the wires as there is a coating on them. So no oil could get on the wires and you sure can't tell if there is a break in a wire somewhere.
I am getting nowhere sourcing a rotor in Canada (at least not for an '83 Heritage Special). Jim, how is that rewinding going? We should talk when you have a moment.
Tested the rotor again - same reading (0.6) as before. So rotor must be toast. Looking at the rotor, it is basically completely sealed. You cannot see the wires as there is a coating on them. So no oil could get on the wires and you sure can't tell if there is a break in a wire somewhere.
I am getting nowhere sourcing a rotor in Canada (at least not for an '83 Heritage Special). Jim, how is that rewinding going? We should talk when you have a moment.
