Generator cover polishing

If it's broken or just needs tweaked

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MJMNY
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Joined: Wed May 28, 2014 7:21 pm

Generator cover polishing

Postby MJMNY » Sun Jan 04, 2015 1:09 pm

My other question: I'm midway through stripping/polishing my engine covers. I removed the generator cover (for the first time; I've only had the bike since May) and discovered the stator bolted firmly inside.

My instinct is to just pop out the three screws and see if I can get it out of the cover, but I'm wondering if anyone has already done this and what I should watch out for. I'd prefer not to break anything if I can avoid it.

Thanks! Matthew

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Folsoml
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Re: Generator cover polishing

Postby Folsoml » Sun Jan 04, 2015 4:32 pm

I've had the stator so stuck in place that I could never get it out, and another time I had the screws holding the brushes so stuck I could not get THEM out. In both cases I ended up finding another complete stator and cover from ebay.

Here are some of the parts I've polished. (The camera angle makes the clutch cover not appear as shiny as it really was.)

Image
Image
Image
Image
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srhiles
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Re: Generator cover polishing

Postby srhiles » Sun Jan 04, 2015 10:34 pm

wow! those look great! what did you use?
srhiles
1981 Honda CB 650
1985 Yamaha Maximum 700x
1998 Yamaha Royal Star 1300 Touring Classic ( husbands bike ) :D

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Folsoml
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Re: Generator cover polishing

Postby Folsoml » Mon Jan 05, 2015 6:18 am

Thanks! I started with about 400 grit sandpaper and worked my way up to 1500 grit. That was just to get the old oxidation and what was left of the clear coat off. Then I used a bench grinder with buffing wheels and used rouges starting with black. Then went gray, white, and finally red.
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srhiles
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Re: Generator cover polishing

Postby srhiles » Mon Jan 05, 2015 1:25 pm

sounds like hard work, but definitely worth it! i have a dremel and thought about using the polish wheels on mine. they already look better than when i purchased my bike but they could always use more shine! Thanks!
srhiles
1981 Honda CB 650
1985 Yamaha Maximum 700x
1998 Yamaha Royal Star 1300 Touring Classic ( husbands bike ) :D

MJMNY
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Joined: Wed May 28, 2014 7:21 pm

Re: Generator cover polishing

Postby MJMNY » Mon Jan 05, 2015 1:44 pm

The only one I've done, so far:

IMG_2440.jpg
IMG_2440.jpg (144.71 KiB) Viewed 7179 times


IMG_2448.jpg
IMG_2448.jpg (132.45 KiB) Viewed 7179 times

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Folsoml
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Location: North Florida

Re: Generator cover polishing

Postby Folsoml » Mon Jan 05, 2015 4:30 pm

Looks great!
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MJMNY
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Re: Generator cover polishing

Postby MJMNY » Mon Jan 05, 2015 4:48 pm

Yours, too!

So, I just took a shot at removing the stator from the cover with a massive screwdriver: those babies don't wanna budge, which seems to be the consensus from EVERYONE.

I still want to get that cover cleaned up, so what I'm thinking is: remove it, along with the cord and plug, as the Clymer manual suggests. Then, I'm thinking I'll cut out a custom gasket to seal the back, so I can go over it with some solvent/water mixture, followed by aircraft stripper. I think as long as I can manage to keep the stator and connections dry, this might be easier in the long run than trying to separate the cover from the stator.

Thoughts??

FordMan
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Re: Generator cover polishing

Postby FordMan » Mon Jan 05, 2015 7:48 pm

Folsoml, when did the "Made In Japan" change from the swoop on the bottom to the straight style right under the Honda Logo, and are yours even 650 covers? thats interesting.
"Vintage Revolution"
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Current:
1979 Honda CB650 (HardTail Build)
1983 Suzuki GS850L (Fix and Minor Restore)
Old:
1989 Suzuki Katana 600
1978 Honda CB400T "Hawk"
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MiGhost
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Re: Generator cover polishing

Postby MiGhost » Tue Jan 06, 2015 3:21 pm

FordMan wrote:Folsoml, when did the "Made In Japan" change from the swoop on the bottom to the straight style right under the Honda Logo, and are yours even 650 covers? thats interesting.

The cover that Larry has is a DOHC cover. Probably off the 750 that he has.
~ Ghost

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Wayward Son:1980 CB650C, RestoMod Period Custom Touring
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MJMNY
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Re: Generator cover polishing

Postby MJMNY » Wed Jan 14, 2015 8:07 pm

How to remove stuck screws.

1) Ensure cover is well-braced; a couple long bolts through where the ones holding it to the engine went, passed through a drilled 2-by-4 or piece of heavy plywood does the trick nicely.

2) Spray a little WD-40 or other lube around the base of the screws.

3) Get a manual impact driver (the kind you hit with a hammer) and fit it with a #3 Phillips bit.

4) Go to town.

I got 4 out of 5 out this way that wouldn't budge, otherwise. The last one was so stuck the impact driver started to strip it. I used a dremel to cut a flathead slot in it (more leverage) and used the impact driver with a flathead bit. Didn't work at first, but used a hammer and chisel on the outside edges of the newly cut slot (trying to use the chisel at an angle to force some counterclockwise rotation). A couple whacks like that, then back to the impact driver, and finally she was loose!

One note: this was my first time using an impact driver. The trick is to push it down and twist as much as possible BEFORE you hit it with the hammer, and keep torquing with your hand as you hit it. Didn't work at all before I figured out the proper way to manipulate it, but, once I did, every one (save that last one) came free with three or four whacks of the hammer.

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Folsoml
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Re: Generator cover polishing

Postby Folsoml » Thu Jan 15, 2015 4:39 am

MiGhost wrote:
FordMan wrote:Folsoml, when did the "Made In Japan" change from the swoop on the bottom to the straight style right under the Honda Logo, and are yours even 650 covers? thats interesting.

The cover that Larry has is a DOHC cover. Probably off the 750 that he has.


Sorry, I somehow missed this post.

MiGhost is correct.
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