84 1/2 alternator question?

[Bastard year]

My 1984 late model's(bastard year) alternator crapped out in Daytona this year. When I returned home and broke her down,I checked output and got 25v. AC instead of 60v.,so I proceeded to replace stator and found some of the magnets on the rotor were chipped.The local HD dealer says that the magnets are not available and I may have to buy the whole rotor/clutch basket assembly.Cost $400.00! I think I could pry out the magnets and replace them just a little cheaper.Any sources,or suggestions?

Thanks,BY

[Fisherman]

This a reply to a previous post:

Coincidence. I was recently researching this very issue in advance of tyre-kicking a 1985 XLX for a mate.

Here's a weblink and two owner experiences emailed to me ... for your further information. Hope this helps.





http://www.heavydutycycles.com/n4sport.htm



Best solution I found was to replace the clutch gear ($80), countershaft gear ($45)(they're a pair) , and clutch hub with a rebuilt unit that Zippers used to market that has thinner magnets for more clearance . They no longer market that unit , but Zippers can direct you to a supplier . Down side to increased stator air gap is diminished charging capacity at low RPM's . BTW , OEM units are around 425 bucks , the rebuilt ones are around 250 . See if they'll let you pull the tranny drain plug (3/4" wrench) when you check the bike out . Fuzz is OK , chunks of magnetic material means there has been contact

I've had to fix my '86 at least a dozen times. chewed up rotor magnets each time. and the ring gear came loose- but welded it together. If you ride conservatively they'll last 'a long time.' if you pull hole shots and put 85hp to it you'll have problems. The whole assembly is a weak point. the whole clutch shell/hub/rotor resides on the clutch gear from the tranny. lots of weight being supported by the splined shaft. the bearings do add some play, but even with new bearings the assembly 'wobbles' a bit. only 50thou clearance between the magnets and the stator. so funny things happen when those ceramic magnets hit the stator. like breakage of said magnets. My 'fix' has been to scour shops that have old baskets laying around and taking out the remaining good magnets from the rotor, then using JB Weld. i've had good success doing this. Replacement parts? the rotor alone is 500 bucks USD, the hub another 150 or so .

Also, there's a place in Canada that replaces / rebuilds these alternators. I'll try & find them again..

[Bastard year]

Thanks Fisherman,
The info you gave is a start,I guess bearings will be in order as this bike has 60,000 + on this clutch alternator combo.I wasn't aware of this design problem.I'm going to scrounge around some used parts locations for magnets.

[Bastard year]

After researching my problem with this clutch basket rotor/stator combo,I found an outfit called Custom MC Services out of Grand Rapids MI..They say they will rebuild mine for $275.00.Has anyone here had any work done by them?

[dwardy]

After researching my problem with this clutch basket rotor/stator combo,I found an outfit called Custom MC Services out of Grand Rapids MI..They say they will rebuild mine for $275.00.Has anyone here had any work done by them?


Nope but if they're in Michigan, they must be good. :D

[Jason's Sporty]

Hey I recently got the clutch drum from V-twin for like $320 from the indy in Erie. This is the one with sealed magnets. The only problem I had with installing it was that it came with the wrong bearing snapring. I just put the orginal in its place.

[BobboJama]

I live close the those guys.... they rebuild the magnet assemblies for a bunch of the H-D Stealerships.... Custom M.C. is straight up and the do excellent work !!
Have no fear...

[Bastard year]

:smoke Just got my basket/rotor back from Custom MC services.Great looking rebuild, magnets are encased in their own frame so if one comes loose it can't separate from the others.They also did some preventive welding around starter gear ring on basket! Highly recommend these guys! :clap

[Fisherman]

Thank you for getting back to us. So many people find fixes & info on a problem & don't tell us about it so there's a lot of refinding & trial & error. My 84 1/2 sporty hasn't had any problems yet but I'm going to sent my 'basket' to these people & have it done so I can forget about this weakness biteing me in the butt later. Again, thanks for the info...