Help - messed up the Alternator lower Pulley case on 1100r?

[snarly]

So I replaced the Hall sensor, reassembled and tightened the alternator - probably too much....
Then I start the bike up, it goes for a couple of minutes then stops.

I look over my work...
first problem - I look at the lower alternator belt crank pulley and alternator belt.

Is the lower crank pulley cover 2 parts - or did i break it? I think maybe i didnt line it up correctly....

Can I fix it or should I replace it?

Any suggestions?
Thanks,
Chris

[omg1010]

Chris, which part do you mean?



Part No. 6? That is one piece. Or which part do you mean?

Brgds
Oliver

[snarly]

Oliver, great pic thanks!
It is #5 - so by the pic it is 2 pieces.
So I did not "break" either piece..but I did bend the groove piece that supposed to line up.

The pulley seemed to rotate in an oval pattern, so I think I did not have it properly lined up.

Would the combination of overtightening the alternator and this bolt cause the bike to not start? Maybe i did something else by lifting the gas tank?

I was able to see the timing set up and think i did that correctly.

Thanks!
Chris

[boxermoose]

Oliver, great pic thanks!
It is #5 - so by the pic it is 2 pieces.
Would the combination of overtightening the alternator and this bolt cause the bike to not start? Maybe i did something else by lifting the gas tank?

It's pretty common to unseat the throttle cables from the ferrules at the throttle bodies - make sure they are both seated and not hung up on the lip

[omg1010]

Chris,

I don't think this is the cause for the bike not starting. The bike starts on battery power and once running the alternator belt drives the alternator which in return charges the battery. It is hard to say why your bike is not starting. I would first check if you have a spark (check the spark plugs) and fuel. And then move on with your investigations.

But you definitely need to correct the pulley and the alternator. The tension of the alternator belt is just right if you can twist the belt by 90 degrees with 2 fingers.

Brgds
Oliver

[snarly]

Thanks guys,
Can somone post a pic of how the tab on the part #5 from the diagram is supposed to be? I think mine is bent but not sure how it should be.

Chris

[omg1010]

Chris, grab yourself the maintenance manual (http://www.carlsalter.com/motorcycle-manuals.asp) and go to section 11.96 ...

Brgds
Oliver

[snarly]

Bike is fixed and running great!
Thanks for the info...I was able to replace and correctly install the pulley, set TPC, correct alternator tension, and placement of Hall sensor.
And - pulling the gas tank did mess up the throttle cables but really easy to put them back.

My neighbor has a 1150 gs and he took mine for a ride.
He was impressed with how smooth the engine was compared to his.

I am very happy with the bike now...it is very quiet...next on the list may be some exhaust changes..

Chris

[omg1010]

Great to hear. Have everlasting fun with your oilhead!

Brgds
Oliver