Stator Rotor issue / question

[Bic]

Test for the electrical guru's. 87 Sporty with charging issues. When we tested the resistance of the stator, it was in spec, but the voltage output was about 1/3 what it should be. Pulled the clutch basket to swap the the stator and inspect the rotor and see this:




magnet removed


One magnet is broken, a second is chipped, the rest I can shift around with my bare fingers (I removed the broken one to demonstrate). I always thought the magnets were fixed, and if there's an issue, you replace the rotor. These magnets are not fixed. See the uneven gap. Some were touching and others not.


Questions:
1) can I get replacement magnets for the 2 damaged or do I need a clutch basket (read this would break the budget)
2) Can I clean and reuse the intact magnets
3) should the magnets be fixed? perhaps I should use some epoxy or JB weld to lock them in place
4) if the magnets come into contact with each other, will that affect voltage output? I understood the function of the charging system to be to create pulses of magnetic fields for the stator winding to pass through, if the magnets are in contact with each other, it would essentially reduce the pulses per rev. Not sure my description makes sense, but I'm curious if this is strictly a rotor issue and not stator at all. Any insight appreciated.

[ted]

Magnets can be cleaned and JB welded back in.
The real problem though, is a sloppy trap door.
The best fix is a Zippers double bearing trap door.

[IamVince]

Dan at NRHS has a lined clutch hub that will also help...my 88 was so bad about that even with a zippers trap door and the lined hub I ended up swapping it for a 99 motor

[Jakeand]

Some more on the subject:

http://xlforum.net/forums/s...t=stator+rotor

http://xlforum.net/forums/s...t=stator+rotor

http://xlforum.net/forums/s...t=stator+rotor

Regards

Jake

[Bic]

Thanks all. Good to know I don't have to fork out for more than a few magnets. Will look into the zippers kit.

[bustert]

this is a common fault with hd alternators. you are fortunate that it did not wipe the entire system out. when the magnet broke, it now forms two magnets and will interfer with the final output. the magnets are spaced as well as the stator winding posts to give a sine wave output but with the magnets messed up, the wave form will be altered and can cancel out each other causing a drop in voltage and amperage. you will not be able to get magnets from hd but you can get a used cup. if you do try to repair the messed up cup, make sure they are evenly spaced and the correct positioning of the poles are correct they should alternate n-s-n-s and so on. if not correct, the wave forms will cancel each other out.
as a note, you can try K&J magnetics to see if they can match the magnet. probably would be better to send an old one to match and replace all of them. sometimes when magnets are thrashed, they will lose some of their strength.

[Bic]

Originally Posted by bustert

this is a common fault with hd alternators. .

I suspected as much. I was going to call HD to order magnets, so thanks for the heads up.