Alternator Rattle

[twinegar]

I am getting ready to pull the alternator and replace the brushes so while I am in there what should I look for that might be making the rattling noise? I put my ear on the cover and it is definitely coming from there. It isn't the clutch.

[alimey4u2]

Looks like you've found the end bearing to be the culprit twine. Leave it upturned on a hot sunny day & it should drop with with a smart tap. Catch it before it wipes out your rotor...

[twinegar]

I am on my way to the auto parts store so can you confirm these part numbers:
6201-2RS-8-12x32x10
6203-2RS-17x40x12

[EMS]

I can confirm the 6201 and its equivalents in the closed and lubed for life varieties for the one in the cover, the 6203 for the one in the housing.

[twinegar]

I spent all afternoon trying to get the outer bearing out of the cover to no avail. I even sat the cover on the stove to get it hot and then chilled the bearing by spraying Gunk carb cleaner and it was still tight. I gutted the bearing leaving only the race and even after cutting through the race on opposite sides couldn't get it to brake into pieces. I finally just robbed the alternator off of my non-running bike and stuck it on the bike. I wonder if the proper puller could have removed it as tight as it is. I might just take it to a shop and see if they can get it out or maybe just buy a new cover to install the bearing into. I buggered the bearing seat in the cover a little bit and don't want to risk a spun bearing. I also have to buy both slip joint plates with the existing ones well worn. They have deep groves but the axial groves or whatever they are are still there.

[Rick Pope]

Warm the outside of the cover with a heat gun or propane torch. Don't need to get it very hot, just so it's unpleasant to hold in your hand. Turn the cover over and slap it down on a block of wood. The bearing should drop out.

Most likely, when you sprayed the bearing to chill it, you cooled the cover somewhat too. Moderate heat is sufficient.

[twinegar]

I tried heating and slamming first with no luck and then tried cooling the bearing thinking it might help. I have separated some tough parts in the past but this one has me stumped. I am going to a couple of specialty tool shops to see what kind of bearing pullers they have. Maybe I can alter one to work. In the end I might need to find a new cover and then press a top of the line bearing in so I don't have to do it again.

[NobleHops]

I spent all afternoon trying to get the outer bearing out of the cover to no avail. I even sat the cover on the stove to get it hot and then chilled the bearing by spraying Gunk carb cleaner and it was still tight. I gutted the bearing leaving only the race and even after cutting through the race on opposite sides couldn't get it to brake into pieces. I finally just robbed the alternator off of my non-running bike and stuck it on the bike. I wonder if the proper puller could have removed it as tight as it is. I might just take it to a shop and see if they can get it out or maybe just buy a new cover to install the bearing into. I buggered the bearing seat in the cover a little bit and don't want to risk a spun bearing. I also have to buy both slip joint plates with the existing ones well worn. They have deep groves but the axial groves or whatever they are are still there.

Sorry, I wish I had posted the first time I saw this. It's surprisingly easy.

Put a towel on your flat workbench.

Heat up the alternator cover from the outside with your heat gun or torch in the location of the bearing.

Pick up the cover (open side down), and bang it sharply on the towel/bench. Take care to hit it flat. My bearing popped out first try.

N.

[twinegar]

Not all assemblies are created equal. Even with just the bearing race left and with the race being cut into two pieces it won't budge. I went through all the earlier posts here before starting and followed all the recommendations to no avail. It's possible that someone used something to seal the bearing in..............the downside of buying used is not knowing. The alternator re-build was going just a little too smoothly when I got to the outer cover. Fortunately I don't keep an eye on market value when I work on my bikes so to relieve the frustration I will in the end probably buy a new cover and set this one on fire.................it is magnesium isn't it?

[EMS]

If it is an original '79, it is magnesium. Before you throw it away, send it to me, I will give the removal a try. Send me a pm or e-mail for the address.

[Will]

If it is an original '79, it is magnesium. Before you throw it away, send it to me, I will give the removal a try. Send me a pm or e-mail for the address.

Mike,

If you can't do it, sent it up the road. I have a tool for doing just that. I made it out of an automotive lifter puller. It's a little 4 pronged gizmo you screw on the end of a slam hammer and just pop it out.

[twinegar]

I appreciate the offer but I already bought a blind bearing remover set. Any time I find I need a tool I try to stock it for later. I could use some original Honda ring compressors though if anyone has any for sale.