Monday, 6 February 2017

SR500 hack - swapping an ignition (pitfalls only)

Smug-grin time.

Thanks to my friend Manuel, I was allowed (again) to borrow a complete SR500 ignition to make sure this was really the matter with the old girl.  If you follow the steps outline in this post, it should take you about 30-40 minutes to swap out both the rotor and stator of the ignition.

Marking her territory like a boss.
As you can see in the pictures above and below, the sprocket cover has already been removed and there's a late 48T-ignition sitting on the tarp. 

The only special tool required is the correct alternator rotor puller, which can be bought via Kedo (and probably some others!) When using it, make sure you put a softer copper washer between the puller and the end of the crank (a 1 cent coin is perfect) to prevent it from galling. Also be aware, that between the rotor and the crankshaft nut are TWO washers.

Once the rotor is removed, the stator is only held on with three bolts and you're pretty much on the home-stretch. The factory manual now claims, that you have to remove the oil-feed line from the engine in order to get the harness out. This is not true, it is sufficient to undo the single bolt holding on the oil and then GENTLY bend the hardline outwards a bit. 

Make sure you've put some threadlock on the end of the crankshaft, as a loose rotor will ruin the crank's taper for sure.

All reassembled and I even cleaned away the oil underneath!

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