Hi to all again.
Continuing to upgrade my Rocket to 12v and electronic ignition.
Have found several issues on the way from previous work done on the bike, but biggest I think was that the alternator rotor had been rubbing on the stator for a long time and had damaged the stator.
Got the replacement today from Paul Goff (good service by the way) and went to fit it. Got my 8 thou all round, tied a piece of string to the old wires and pulled them through, tied on the new wires and found that the new sheathing is bigger and got stuck as i pulled it through and lo and behold the string came away.
I've tried pushing various things into the hole but cannot get anything to come through.
Can anyone advise me as to how to get the new wires through and where they exit near the left hand coil. Can it be seen with the chain guard off or am I in for a big job? Think I'll have to at least cut back the sheathing and fit smaller heat shrink tubing once I know how to get it through.
Thanks
Clarke
If the same as the oil in frame models the wires emerge on the other side of the primary case wall just below the breather port. Screw drive blade pointing to it in the photo.
Hi Clarke,
Threading the wires through is always a pain. As you have lost the advantage of a piece of string try threading a piece of electrical wire through. Put a bit of a bend in it so that as it exits the tube from the primary case it turns right, towards the rear of the bike. If you are lucky it will appear somewhere near the rear engine plates first time. You may have to try a few times. Once successful attach the single wire to the end of the alternator wires and use tape to smooth out any edges of the sheathing and taper it to the single wire. Use some WD40 to help things to slide. Push the alternator leads as you pull lead wire. Hopefully this will work for you as it has for me.
Dave.
Hi and thanks for the replies.
I did manage to thread a single wire through and if I'm right it comes out under the engine/gearbox and up just outside where the drive chain exits the primary side.
Still no hope of getting the wires from the stator through so I'm going to cut them and solder new wriest them once I've got the wires where I want them.
Did this earlier today but I only had 1mm square wire or thicker ones from a solar powered battery charger which also proved too thick.
I'll order some 2mm square wire and give it another go. I'll use shrink fit sheathing over the joins.
I thought from past experience with my Triumph which had a similar problem that getting the air gap at the stator/rotor was going to be the problem but this has been a nightmare.
Thanks again.
Clarke