Alternator rotor bolt Loose ?!?!
- otakar
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01 Sep 2010 14:44 #395451
by otakar
74 Z1-A stock
76 KZ-900 Totaly stock vice MAC pipe
77 KZ-1000A stock
78 Z1-R 100%MINT 500 original Mi.
78 Z1-R Yoshi 1103 kit stage 1 cams Yoshi pipe. Etc
79 KZ-1300 (1400)
80 KZ-1300
81 Scratch built GPz1150R
82 KZ1000
Alternator rotor bolt Loose ?!?! was created by otakar
:ohmy: I have never run into this in over thirty years of messing with these things.
This morning I was going to take my bike for a spin. Low and behold the starter turned but the engine did not. The first thing that came to mind was a bad starter clutch. This was totally unexpected because i have never before had a stitch of trouble. This was the first time this has ever happened. I took the bike in the garage and removed the alternator cover, removed the reduction gear and gave the gear a spin. Huh everything turned just like it was supposed to. With the exception of the crank shaft. The bolt holding it to the crank had loosened up????????? WTF. Any ideas why??? Should there be Locktite on that bolt? There is no Wudruf key just a taper.
This morning I was going to take my bike for a spin. Low and behold the starter turned but the engine did not. The first thing that came to mind was a bad starter clutch. This was totally unexpected because i have never before had a stitch of trouble. This was the first time this has ever happened. I took the bike in the garage and removed the alternator cover, removed the reduction gear and gave the gear a spin. Huh everything turned just like it was supposed to. With the exception of the crank shaft. The bolt holding it to the crank had loosened up????????? WTF. Any ideas why??? Should there be Locktite on that bolt? There is no Wudruf key just a taper.
74 Z1-A stock
76 KZ-900 Totaly stock vice MAC pipe
77 KZ-1000A stock
78 Z1-R 100%MINT 500 original Mi.
78 Z1-R Yoshi 1103 kit stage 1 cams Yoshi pipe. Etc
79 KZ-1300 (1400)
80 KZ-1300
81 Scratch built GPz1150R
82 KZ1000
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- testarossa
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- Attack life, it's only trying to kill you.
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01 Sep 2010 14:50 #395452
by testarossa
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
Replied by testarossa on topic Alternator rotor bolt Loose ?!?!
Is the tapered end of the crankshaft gaulled? It happened to the PO of my bike(78 KZ1000A2). That bike didn't have a woodruff key either. I'm not sure why it happens, but mark1122 told me about the same problem with one of his bikes.
1978 KZ1000 A2 Click--->Build Thread
2004 ZX-10R
2007 Harley Sportster 1200
2020 Harley Street Glide Special
Angola, IN
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- jeffasaki
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01 Sep 2010 15:21 #395460
by jeffasaki
78 Z1R
78 KZ1000
76 KH500 gone
71 HS1B 90
81 GS 1100 gone
80 PE400
02 KLR
Ontario Canada
Replied by jeffasaki on topic Alternator rotor bolt Loose ?!?!
Hey Otakar,I had the exact problem with one of my KZs.This how I solved the problem.First of all there is 2 styles of rotors one keyed and one not.You have the one that is not,same as me.There are 3 different thicknesses of gear dampers avaiable.you have to assemble the complete assy without one in there you put a little ball of clay where the damper goes do the assy then take it apart and measure it to determin what size you need.(they are still avaiable from Kawi)I bought all 3.I went through this hell a few times with the same result,rotor popping offas soon as the bike fired.I inspected the contact surfaces of the taper area,Put some machinests ink on(a very light coat)and torqued it up.I found that the surfaces where not a perfect match and thought this is probably normal as they would reqire proper torque to mate up.I was wrong.I spoke with a Kawasaki God named Gord Bush and he advised me to lap the 2 parts together whitch I did.I didnt use lapping compound I used some mothers aluminium polish.Took my time and had a beer while I did it.Finally before final assy i cleaned out the theads in the crank taper with a tap and some brake cleaner,cleaned the bolt with a wire wheel.put on some RED locktite and assembled it.Let it sit overnight.checked it the next morning with the cover off,and it all held together.Hasnt been a problem since. You gotta torque the unkeyed rotors to 95 ft/lbs,the book says never hit it with a hammer(you could destroy the magnetisum,I gave it a tap using a piece of 2x4 for a drift before I torqued it.Whatever you do DO NOT let that rotor spin with the engine running itll chew the shit out of the taper on the end of your crank.Ive seen the results of this and its NOT GOOD.
Hope this works for you
Jeff
Hope this works for you
Jeff
78 Z1R
78 KZ1000
76 KH500 gone
71 HS1B 90
81 GS 1100 gone
80 PE400
02 KLR
Ontario Canada
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- otakar
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01 Sep 2010 15:24 #395461
by otakar
74 Z1-A stock
76 KZ-900 Totaly stock vice MAC pipe
77 KZ-1000A stock
78 Z1-R 100%MINT 500 original Mi.
78 Z1-R Yoshi 1103 kit stage 1 cams Yoshi pipe. Etc
79 KZ-1300 (1400)
80 KZ-1300
81 Scratch built GPz1150R
82 KZ1000
Replied by otakar on topic Alternator rotor bolt Loose ?!?!
I just talked to a local racer who rides a 1500cc GPz. He said it has happened to him a few times on the bike. He stated that is a common problem on hi compression motors. He told me to lap the tapers into each other, put some locktite on the taper and tighten with an impact wrench. That's what I did. The whole job took me about an hour.
74 Z1-A stock
76 KZ-900 Totaly stock vice MAC pipe
77 KZ-1000A stock
78 Z1-R 100%MINT 500 original Mi.
78 Z1-R Yoshi 1103 kit stage 1 cams Yoshi pipe. Etc
79 KZ-1300 (1400)
80 KZ-1300
81 Scratch built GPz1150R
82 KZ1000
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- jeffasaki
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01 Sep 2010 15:35 #395464
by jeffasaki
78 Z1R
78 KZ1000
76 KH500 gone
71 HS1B 90
81 GS 1100 gone
80 PE400
02 KLR
Ontario Canada
Replied by jeffasaki on topic Alternator rotor bolt Loose ?!?!
If you put locktite right on the taper its gonna fail again.That surface needs to be clean as a whistle where the 2 tapers meet.Ive already gone trough this nightmare.
78 Z1R
78 KZ1000
76 KH500 gone
71 HS1B 90
81 GS 1100 gone
80 PE400
02 KLR
Ontario Canada
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- Motor Head
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- FIX UP YOUR BIKE RIGHT AND CHEAP
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01 Sep 2010 16:03 #395467
by Motor Head
1982 KZ1000LTD K2 Vance & Hines 4-1 ACCEL COILS Added Vetter fairing & Bags. FOX Racing rear Shocks, Braced Swing-arm, Fork Brace, Progressive Fork Springs RT Gold Emulators, APE Valve Springs, 1166 Big Bore kit, RS34's, GPZ cams.
1980 KZ550LTD C1 Stock SOLD Miss it
1979 MAZDA RX7 in the works, 13B...
Replied by Motor Head on topic Alternator rotor bolt Loose ?!?!
My 82 1000/ 1100 FSM Says 116 Foot pounds for the Rotor bolt, Tighten then loosen and re-torque. Clean taper with a high flash point solvent. Also says if parts are replaced then different thickness dampener may be needed, there also different thickness thrust washers, etc.
1982 KZ1000LTD K2 Vance & Hines 4-1 ACCEL COILS Added Vetter fairing & Bags. FOX Racing rear Shocks, Braced Swing-arm, Fork Brace, Progressive Fork Springs RT Gold Emulators, APE Valve Springs, 1166 Big Bore kit, RS34's, GPZ cams.
1980 KZ550LTD C1 Stock SOLD Miss it
1979 MAZDA RX7 in the works, 13B...
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- Kawickrice
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01 Sep 2010 18:54 #395495
by Kawickrice
73 Kawasaki Z1
07 HD CVO Ultra Classic
82 Suzuki GS 1100
74 Yamaha RD 350 (My two stroke toy)
77 Kawasaki KZ 650B-1 (My putt around bike)
80 Indian Moped (My American Iron)
1
Long Gone
75 Suzuki GT550
74 GT 380
79 RD 400 Daytona Special
72 Honda CL 175
74 Honda QA 50
Tampa FL
Replied by Kawickrice on topic Alternator rotor bolt Loose ?!?!
The same thing happened to me, took me 3 trys to get it right, loctite and an impact did the trick.
![:) :)](/media/kunena/emoticons/8.png)
73 Kawasaki Z1
07 HD CVO Ultra Classic
82 Suzuki GS 1100
74 Yamaha RD 350 (My two stroke toy)
77 Kawasaki KZ 650B-1 (My putt around bike)
80 Indian Moped (My American Iron)
1
Long Gone
75 Suzuki GT550
74 GT 380
79 RD 400 Daytona Special
72 Honda CL 175
74 Honda QA 50
Tampa FL
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- 82Kz1100ccSpectre
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14 Jun 2024 06:38 #900709
by 82Kz1100ccSpectre
Replied by 82Kz1100ccSpectre on topic Alternator rotor bolt Loose ?!?!
What does lapping the taper mean? I am having the exact same problem. Changed out the motor clutch and put all back together and used red lock tite…it worked 3 or 4 times but then failed.
can someone explain to me to exact way to repair this? This bike has been nothing but problems for me…I thought I had the right idea…obviously not.
thank you
can someone explain to me to exact way to repair this? This bike has been nothing but problems for me…I thought I had the right idea…obviously not.
thank you
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- SWest
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- 10 22 2014
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14 Jun 2024 07:03 - 14 Jun 2024 07:05 #900711
by SWest
Replied by SWest on topic Alternator rotor bolt Loose ?!?!
Lapping the taper means use a small amount of lapping compound on the taper until it becomes even by sight. Clean thoroughly so none of that grit gets in the engine. Easy on the red locktight.
Steve
Steve
Last edit: 14 Jun 2024 07:05 by SWest. Reason: sp
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- TexasKZ
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14 Jun 2024 07:40 #900713
by TexasKZ
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Replied by TexasKZ on topic Alternator rotor bolt Loose ?!?!
You will need to buy some lapping compound, which is an abrasive paste. Disassemble the alternator and carefully clean both the crankshaft taper and the opposite taper inside the rotor. Apply some compound to the taper and then carefully, and gently slide the rotor onto the crankshaft until it lightly makes contact, then rotate the rotor back and forth by hand so the compound begins to polish the two tapers. After a bit, pull the rotor off, carefully clean the surfaces and repeat. Each time you clean off the surfaces, pay close attention to the polished areas on both pieces. As the compound removes the high spots, the polished areas will get more and more uniform. Ideally, you want a fully uniform look on both parts, but this may not be entirely possible, depending on the severity of the damage.Once it is as good as you think it can get, clean, clean clean the parts, and reassemble.Do not leave any specs of the compound behind, for they can come back to bite you in the heiny later.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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- TexasKZ
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14 Jun 2024 07:43 #900714
by TexasKZ
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Replied by TexasKZ on topic Alternator rotor bolt Loose ?!?!
Wow. resurrecting a fourteen year dead thread. Is this a record for KZR?
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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- zed1015
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14 Jun 2024 08:09 - 14 Jun 2024 09:42 #900715
by zed1015
AIR CORRECTOR JETS FOR VM CARBS AND ETHANOL RESISTANT VITON CHOKE PLUNGER SEAL REPLACMENT FOR ALL CLASSIC AND MODERN MOTORCYCLE CARBURETTORS
kzrider.com/forum/23-for-sale/611992-air-corrector-jets-
Replied by zed1015 on topic Alternator rotor bolt Loose ?!?!
Be careful when lapping the taper.
Going too far ( which does't take much ) can reduce the clearance for the starter gear and associated shims for the needle roller which can cause the starter gear to bind and drive the starter motor at the very least.
Also never apply loctite to the actual taper, just non permanent 'blue" thread lock to the rotor bolt threads.
The crank taper and rotor must remain metal to metal contact.
Going too far ( which does't take much ) can reduce the clearance for the starter gear and associated shims for the needle roller which can cause the starter gear to bind and drive the starter motor at the very least.
Also never apply loctite to the actual taper, just non permanent 'blue" thread lock to the rotor bolt threads.
The crank taper and rotor must remain metal to metal contact.
AIR CORRECTOR JETS FOR VM CARBS AND ETHANOL RESISTANT VITON CHOKE PLUNGER SEAL REPLACMENT FOR ALL CLASSIC AND MODERN MOTORCYCLE CARBURETTORS
kzrider.com/forum/23-for-sale/611992-air-corrector-jets-
Last edit: 14 Jun 2024 09:42 by zed1015.
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