Alternator failure - - Excellence in Motion
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post #1 of 2 (permalink) Old Apr 19th, 2008, 9:56 pm Thread Starter
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Join Date: Jun 2003
Location: Melbourne, Victoria, Australia
Posts: 1,163
Alternator failure

I posted a message in tech. on behalf of a ride pal who does not have computer access. Seems like he does not need advice, the problem seems obvious. Here is the story so far. 2003 K GT, 60,000K's up. Whining noise at start, no alternator. Strips the bike down. Pictured is the driving dog which connects the alt. to the motor drive. Also pictured is the bolt that holds the dog.

Theory...Some underpaid illegal immigrant has fitted the dog, the bolt has snapped. He does not give shit, proceeds with the assembly. The bolt has flopped around inside the spline, wrecking the thread, the spline has moved backwards and forwards stripping itself, finally the dog will not spin the alt.

He now has to remove the gear box/clutch and replace the drive spline which has a broken bolt end inside and has worn out threads. I suggested he may have shot himself in the foot by not having the work done at a BMW shop. It is at least a 20 hour job, but how can he attack the manufacturer if he has done half the work himself. As you can see in the pic, the bolt has broken, and has been for some time by the surface rust etcetera. Sure hope mine is in better shape. The dog pictured is the used replacement part, it has good splines.

(point of interest. When he was at the wreckers yard he saw his old K1100RT, much damaged. The head had been removed for fitting to a late model Mini Minor)
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Last edited by Papilio; Apr 19th, 2008 at 11:11 pm.
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post #2 of 2 (permalink) Old Apr 20th, 2008, 4:51 am
Join Date: Mar 2004
Location: , , UK
Posts: 3,750
Certainly some lessons to learn there.

I'm not a perfect wrench, but I've learned enough to know that these bikes need patience and careful conscientious work.

I'm not sure where the case against the manufacturer is. I'd worry about any other parts of the bike that monkey has assembled.

Are you sure the alternator didn't get something inside it, or bearing wear caused the rotor to lock up, the clearances are pretty tight? Is it spinning nice and free? Before putting it back I'd try and spin it up and see if some volts came out. At least split the covers and have a good look inside it.

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