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Date Posted: Thu August 07, 2008 11:16:21AM
Author: Rick in NYC
Subject: Trip Interupted

On Saturday, my wife on her Burgman 400, and me on my 1996 VXII was traveling from NY to Cape Cod, Mass. for weekend getaway. It was a sunny afternoon and I was 4 hours/210 miles into my trip. The bike was running great and I was saying Life is Good. Suddently I watched in horror as my voltmeter went from 13.5 volts to 11.6.

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I immediately turned off the radio, CB, GPS, foglights, headlight and running lights. In case some of you have never turned off the headlight, here is how to do it: Start the bike in neutral. With your right hand, rev the motor slightly, at the same time, with your left hand, turn your ignition key from run, to accessory, back to run quickly. The bike will stay running with no lights on. To put the headlight back on, tap the Starter button. Althought the voltage went up to 11.8, it did not increase when I reved the motor; I knew I had a bad alternator.

I pulled off the highway into a Shell gas station. Although they had gasoline and coffee, they did not have any repair facilities. I left the bike there and continued to the Bed and Breakfast in Cape Cod on the wife's Burgman.

I called my brother Frank for help. He removed his alternator from his 1997 VXII and drove to my location Sunday morning.

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A quick check with a voltmeter confirmed no voltage output. To remove the alternator, remove screws on chrome cover and 3 mounting bolts. You also need to remove the coolant bottle to get at the connector plug.

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Be carefull not to lose the 4 black plastic coupling pieces.

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With the bike now running, I continued to Cape Cod. Had a wonderfull time in this charming seaside community.

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The lighthouse at Chatam Harbour.

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Back home I took apart the alternator. Use rag to hold fins from spinning, remove center bolt.

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Remove 4 screws underneath. Remove wire harness leads on bottom.

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Next use a new #3 tip philips screwdriver to remove stubborn case bolts.

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Scratch a mark on the case for correct re-assembly.

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Split the case.

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Remove 4 screws to voltage regulator and rectifier.

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Use soldering gun to detach 3 soldier joints from stator windings to rectifier.

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I used a ohm meter to test the resisters: they were all to factory specs.

I then tested the rotor coil slip rings. I found the cause of the no voltage output. It had an open wire in the rotor windings. See the voltmeter reading's kiss of death: O.L.

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I reassembled the alternator and brought it to a local alternator shop. The repairman stated Mitsubishi alternators are notorous for rotor failings. Time to call Carl Leo for a used alternator........

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