where is the generator ?

[mikes2]

Hi everyone.

Got myself another odd ball. A 1989 GK74 GSX400F.
Its the GSX600F Teapot with the 400R engine so ive been told.

Im going through the electrics as its not pumping out much voltage. Ive checked everything and replaced most of it.
Just wondered where the generator is mounted ? is it behind one of the covers on the end of the crank shaft ???
Also where can I get gaskets for both left & right engine side covers.

Thanks

Mike

[SevenThreeSeven]

The generator is located on the right-hand side of the engine, on the end of the crankshaft. The three yellow wires (three AC phases) from the generator come out the top of the case and lead to the plug on the Rectifier/Regulator.

The generator itself rarely fails, there's nothing in there to actually "wear out". So it's usually a fault in the wiring or a problem with the Rectifier/Regulator itself.

If your bike isn't charging well the first check would be the condition/continuity of this wiring. There are three yellow wires leading from the generator (on the right-hand side of the engine) to the Rectifier/Regulator and two wires (one red, one black/w white stripe, I think) leading away from the Rectifier/Regulator into the bike's wiring harness. Sometimes the connector plug gets corroded (sometimes badly) and then it can heat up become partially or completely melted.



(in this picture the generator is the round thingy just in front of the the clutch basket. it's the thing that is sticking out the farthest.)

I replaced the old R/R (thyristor type, shown on the right of the picture) that was failing on my bike with a newer technology R/R (MOSFET type, from an '07-'08 Yamaha YZF-R1, shown on the left of the picture).

[mikes2]

I have replaced the regulator/rectifier already and a few melted wires.
Will check the wiring to the generator next.

Thanks :)

[mikes2]

OK so I checked all the wiring all good. All connectors are good. New regulator / rectifier fitted.
Pulled the engine cover off to check generator and it looks like someone has been at the generator before me.
Looking at the windings through the small hole and its a bit chewed up in there. Think someone has jammed a screwdriver inside it to loosen the bolt.

How does the generator come off ? I took the 17mm bolt out but the generator didnt move.

Do I need a puller ???

[SevenThreeSeven]

How does the generator come off ? I took the 17mm bolt out but the generator didnt move.

Do I need a puller ???

Yes, you have to use a puller. Suzuki doesn't call it a "puller". They call it "Special Tool 09920-13120: Crankcase Separating Tool". Here's what it looks like in the Suzuki maintenance catalog:






Here's a shot of page 3-13 in my GSF400 Bandit Service and Repair Manual (the Bandit's 400cc engine is a K707 prefix code):



In the top picture on this page they show the process of loosening (but not removal) of the rotor bolt. You don't take the rotor bolt all the way out because the puller uses it as a press-point to exert force on when you're getting the generator rotor to pop off the end of the crankshaft.

In the middle picture on this page you can see that the puller ("Special Tool 09920-13120: Crankcase Separating Tool") has three legs that screw into the generator rotor. Then you tighten the center of the puller until the rotor pops loose.

Looking at the windings through the small hole and its a bit chewed up in there. Think someone has jammed a screwdriver inside it to loosen the bolt.

Wow, that sounds bad. Obviously there's a "right way" and a "wrong way" to work on an engine.

I don't know what you used to hold the generator rotor stationary while you got the rotor bolt loose but Suzuki has another "Special Tool" for that purpose. It's called "Special Tool 09930-32420: Rotor Holder". It screws onto the generator rotor and it has a long handle that you use for leverage against the wrench you're using on the rotor bolt. Here's a picture of it from the maintenance catalog:

[mikes2]

Spot on thanks for that.

Will make a wee puller up at weekend