R1 Engine Generator problem (1999)

Alright guys. At uni now and my first project on the go between me and 2 other guys is a strip down, clean up/ service, modification and re-build of a 1999 R1 Engine...

The full reason is none of us know anything about engines so we wanted to work on one to 'try' and learn something.

The engine is from a track bike and looks as if it has been stripped and re-assembled before.

The problem we are having is trying to remove this...




Most seem to believe it is pressed on/ held in place by the stator and there is no thread that actually holds it in place. The thread in the centre is for the generator cover bolt...

Either way it is on ridiculously tight and is not coming off. We've tried using pullers but just damaged them and the generator. We have even gone as far as trying to fabricate our own pulling plate mechanism. The aim was to tap the holes in the generator but the metal is surprisingly soft and as it is so thin, we can only manage 2 threads which will just be ripped out with any force.

Any ideas??? We think we may just have to perhaps cut it off somehow. We are prepared to replace the generator, would like to save the stator and definitely want to save the crankshaft.

Thanks very much.

[rictus01]

bolt of the right size in the middle thread, do it up fairly tight, sharp rap with a hammer on the end of the bolt and it'll pop off in all probability.

Cheers Mark.

Cheers dude. We did try that one but it is not budging. No one in the workshop can understand why it is on so tight. We expected to be able to do what you mentioned but it won't move. We've been on it for days now, we think last time it was put back on it may have been done on the p1ss a little bit.

Cheers.

[rictus01]

if as you say that didn't work try an air impact gun on the bolt it may do the job.

Cheers Mark.

[rictus01]

you might get a small puller through the holes too as another suggestion ?

That idea would be the way forward but we'd need a 5 Tonne puller... Apparently it's quite a common problem

We're just gonna have to cut it off now as we can't afford to buy the puller and the new rotor that we need as we f***ed this one...

Bad times but lesson learned.