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Discussion Starter · #1 ·
Three months ago I dealt with the alternator shaft broken bolt syndrome. When re-installing the alternator, I was very careful not to pinch the O ring. Got to work this morning, oil all over the side stand and underneath. At first I thought it was the countershaft or output shaft seal, but following the oil trail, I tracked it down to the alternator. I'm bummed out that I have to do it again and I just needed to vent.
Thanks.
 

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Sucks, Zeb. I hate that bottom bolt and getting it around the coolant hose! I had a hard time getting mine in after having the alternator rebuilt and tore two myself. I found a light coating of grease both on the alternator (with o-ring installed) and on the housing was just the trick.

Scott
 

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Discussion Starter · #5 ·
I hate that bottom bolt and getting it around the coolant hose! I had a hard time getting mine in after having the alternator rebuilt and tore two myself.
Yeah, that bottom bolt is a PIA. That and the little rubber impeller bumper things in there. One or two always falls down. I used a little silicone the last time. But I did get her fixed today. Fortunately next door to my shop is a bike shop called Motoworks, they had the right size o-ring in stock. Guess I wasn't careful enough when I installed it the last time, the o-ring came out in two pieces. Hope to not have to go thru that again.
 

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Probably obvious but the o-ring needs to be lubed with engine oil.
 

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I used thick grease to hold the rubbers in place, and after chewing the new o-ring to bits I left it out and just used silicone. That was about 3 years ago and it's still holding out :D.
 
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