Topic: Alternator rotor stuck - help please

[Cevan]

Disassembling my 500K1 engine.  The rotor is really stuck.  I literally stripped the M16 removal bolt.   I used progressively more air in my impact gun and disaster.   I have a three leg puller on it now and nothing is budging it.   I’ve tried heating it for 10 full minutes and nothing. 

Any suggestions?

[bryanj]

If you have put that much heat in yes it does need to come off to replace the crank seal behind it, a 3 leg puller will have damaged the rotor, crank or both but it doesnt need to come off to split the cases and remove crank assembly
You need the proper 4 way honda puller and a hide mallet, never failed me yet

[Bodi]

Stripped the bolt or the rotor threads? The Honda tool is a hardened "bolt", if you used a hardware store bolt I'm not surprised that it stripped.

[HondaMan]

Yeow!
Yeah, they get stuck: I use extensive heating with a MAPP gas torch of the rotor, myself. Heat guns and propane almost never work. When it starts smoking off the old oil on it, it's getting close to ready. Keep a fire extinguisher handy as old oil starts to burn at those temps.


Then polish the end of the crank and the ID of the rotor with fine Scotchbrite before reassembly. It will take about an hour to cool.

[Don R]

 The big Suzuki's are known to spin the rotor on the crankshaft, one of the cures is supposedly to get it warmed up and rattle it onto the crank while it's expanded.

[Dr. Frankenstein]

I have a 500K too, I was really surprised to see that there isn't a woodruff key on the end of the 500K shaft...I used the Honda bolt to get mine off, but I was surprised to not see a woodruff key on it.

[bryanj]

Dont need it, they get damned tight without, although there was a bulletin fot early 750 altering the torque for the bolt but that has the starter clutch on the back as well

[Cevan]

I got it free. The crank is undamaged. What stripped was the extractor bowl which I thought was hardened steel. Was not a hardware store bolt.Will need to source a new rotor. I hit it with some PB blaster overnight and then went at it with more heat.  Eventually popped right off.

[HondaMan]

Good job!
Merry Christmas!

[bryanj]

Any 500 or 550 rotor is the same

[MauiK3]

Great news, I hope finding the rotor isn't too hard.

[Cevan]

There’s a few on EBay.  I’ve got a ways to go before I need it.  Here’s the current state of the engine.  Not sure what happened.  😀

[HondaMan]

There’s a few on EBay.  I’ve got a ways to go before I need it.  Here’s the current state of the engine.  Not sure what happened.  😀

It musta been goin' mighty fast!