Reinforce magnets before they fail? - SV1000 Portal
 2Likes
Reply
 
LinkBack Thread Tools Rate Thread Display Modes
post #1 of 18 (permalink) Old 8th May 2020, 07:46 PM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
Reinforce magnets before they fail?

Hey all, 2003 SV1000s ~25k miles. Doing some wrenching and took off the generator cover to check for magnet issues while the bike is on the stand. To my pleasant surprise, they all seem secure, but wondering if an ounce of prevention is best here? From what I can gather, magnet failure would be pretty bad on the side of the road? I've seen some threads of people using JBWeld in between and smoothing it all out, but should I let them be until there are any symptoms?

Thanks all!
Attached Images
File Type: jpg 2020-05-08 15.25.13.jpg (564.5 KB, 69 views)
gregmontalbano is offline  
Sponsored Links
Advertisement
 
post #2 of 18 (permalink) Old 8th May 2020, 08:05 PM
Bike curious
 
oldbaldsob's Avatar
 
Join Date: May 2005
 ♂ United States
Springfield, MOFO
Posts: 8,641
Garage
Quote:
Originally Posted by gregmontalbano
....but wondering if an ounce of prevention is best here? From what I can gather, magnet failure would be pretty bad on the side of the road? I've seen some threads of people using JBWeld in between and smoothing it all out, but should I let them be until there are any symptoms?

That bottom magnet has slipped out of position. Notice the gap differences between the rest of your magnets. To remove it, carefully heat the outside of the flywheel with a heat gun or torch and gently pry it up with a screw driver. Then you can file the glue off that magnet, put a thin smear of JB Weld on it then reposition it correctly. After it hardens, you can then put JB Weld between the rest of them.

Some members have been lucky not to have their magnets come loose but lots of people have with varying degrees of damage. I preemptively immobilized the flywheel magnets on my '06 with JB Weld. Now I have peace of mind that they won't move. Peace of mind is worth a lot when you are out on the road far away from home.
PEZ and 07blacksv1ks like this.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.



Two of my favorite posts here on the SV Portal are by Chainsaw Willie!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
and
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
.
oldbaldsob is offline  
post #3 of 18 (permalink) Old 8th May 2020, 08:21 PM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
Can't argue with that! I actually just found your post on this, looks very solid (won't let me link to the post). I suppose it would be wise to do the same.

Quote:
Originally Posted by oldbaldsob View Post
That bottom magnet has slipped out of position. Notice the gap differences between the rest of your magnets.:
I had noticed but since they felt so secure I somewhat assumed it was normal. Good catch, thank you!

Edit: Which JB Weld product did you use?

Last edited by gregmontalbano; 8th May 2020 at 08:24 PM. Reason: add question about product
gregmontalbano is offline  
 
post #4 of 18 (permalink) Old 8th May 2020, 08:55 PM
Bike curious
 
oldbaldsob's Avatar
 
Join Date: May 2005
 ♂ United States
Springfield, MOFO
Posts: 8,641
Garage
My pleasure! The original glue used on the magnets loosens with age and heat which allows the magnets to slide but then hardens again after it cools down.


I used the two-part mix that has a tensile strength of 3960 psi and can withstand temps of 550 degrees when fully cured. Others have used the stick putty which I think has a bit lower temp rating. The putty is much easier to work with but I can't speak to it's effectiveness. It will probably work just fine though. There is the possibility that the flywheel can become unbalanced but with even application and some sanding after it hardens should be satisfactory.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.



Two of my favorite posts here on the SV Portal are by Chainsaw Willie!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
and
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
.
oldbaldsob is offline  
post #5 of 18 (permalink) Old 11th May 2020, 04:28 PM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
Wow, so glad I went down this rabbit hole...after even FURTHER investigation, three magnets popped off with ease. I'll be removing all, cleaning and re-attaching, following the guides and advice in other posts (and oldbaldsob's here, thanks again!). It seems pretty straightforward, and will post back with results in case anyone else is either attempting or deciding if they should (they should!).

Another question, when removing the cover, the gear on the bottom left that seems to attach the magnet basket to the other gears fell out, and the basket rotated slightly, is there any concern about it rotating and affecting the position of anything inside the engine? Thinking along the lines of a timing belt replacement on a car, gotta keep everything in the same position.
gregmontalbano is offline  
post #6 of 18 (permalink) Old 12th May 2020, 01:31 AM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
To clarify, it seems like the starter idle gear fell out, and the gear behind the flywheel (starter driven gear?) rotated clockwise a few positions. Would this cause an issue when trying to start again? From what I can tell by pouring over the service manual, no...but, want to be sure!
gregmontalbano is offline  
post #7 of 18 (permalink) Old 12th May 2020, 01:58 AM
Bike curious
 
oldbaldsob's Avatar
 
Join Date: May 2005
 ♂ United States
Springfield, MOFO
Posts: 8,641
Garage
Quote:
Originally Posted by greg montalbano
....Would this cause an issue when trying to start again? From what I can tell by pouring over the service manual, no...but, want to be sure!

Nope, just fit it back in with the correct spacers and there won't be any problems. The starter idle gear fell out on both of my SV1000s when I took the case covers off. The only time you need to be mindful of engine position is when the cams are out and you are checking valve clearances. Glad you are taking care of those magnets!


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.



Two of my favorite posts here on the SV Portal are by Chainsaw Willie!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
and
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
.
oldbaldsob is offline  
post #8 of 18 (permalink) Old 16th May 2020, 04:44 PM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
Very unfortunate development. I’m sitting here with everything I need to put my (fortunately in good condition) magnets back in, and I’m sanding the Epoxy off the back of one magnet. A wasp, a now dead wasp, flys right into my face, the magnet goes flying and cracks. Unbelievable. Once magnets break they are unusable, I believe. Even if glued together, they’ll be out of phase.

In addition to venting, I’m soliciting ONE replacement magnet, all I need. If anyone has any leads, please let me know! Searching the usual places for donor parts etc but I’d love for this wasp to not have cost me the price of an entirely new stator rotor!
gregmontalbano is offline  
post #9 of 18 (permalink) Old 16th May 2020, 05:14 PM
Bike curious
 
oldbaldsob's Avatar
 
Join Date: May 2005
 ♂ United States
Springfield, MOFO
Posts: 8,641
Garage
TBH, if it is just a crack, I would be the guy to JB Weld it into the flywheel. I think there is enough of a magnetic field generation in the remaining magnets which would easily compensate for any weakness in that magnet.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.



Two of my favorite posts here on the SV Portal are by Chainsaw Willie!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
and
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
.
oldbaldsob is offline  
post #10 of 18 (permalink) Old 16th May 2020, 05:23 PM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
Pretty much in half...
Attached Images
File Type: jpg image_1589649790258.jpg (514.4 KB, 23 views)
gregmontalbano is offline  
post #11 of 18 (permalink) Old 16th May 2020, 05:30 PM
Bike curious
 
oldbaldsob's Avatar
 
Join Date: May 2005
 ♂ United States
Springfield, MOFO
Posts: 8,641
Garage
I seem to recall at least one person who JB Welded a broken magnet together and used it. I'd have to search through the magnet threads for that info. If it were me, I'd probably do it. I still think there would be adequate magnetic field generation.

I found a flywheel magnet for a boat motor on eBay here: https://www.offshoremarineparts.com/...ription_tabbed

I have absolutely no idea about the dimensions, weight, etc. but it might be worth checking into.


To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.



Two of my favorite posts here on the SV Portal are by Chainsaw Willie!
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
and
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
.
oldbaldsob is offline  
post #12 of 18 (permalink) Old 16th May 2020, 05:35 PM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
Fair enough! Will do some more research, Still waiting on other parts so this isn’t a blocker, will keep everyone updated. Thank you!
gregmontalbano is offline  
post #13 of 18 (permalink) Old 17th May 2020, 07:42 AM
L-Plate Rider
 
Join Date: Oct 2019
Australia
Sydney
Posts: 1
Quote:
Originally Posted by gregmontalbano View Post
Very unfortunate development. I’m sitting here with everything I need to put my (fortunately in good condition) magnets back in, and I’m sanding the Epoxy off the back of one magnet. A wasp, a now dead wasp, flys right into my face, the magnet goes flying and cracks. Unbelievable. Once magnets break they are unusable, I believe. Even if glued together, they’ll be out of phase.

In addition to venting, I’m soliciting ONE replacement magnet, all I need. If anyone has any leads, please let me know! Searching the usual places for donor parts etc but I’d love for this wasp to not have cost me the price of an entirely new stator rotor!
Hey mate, at least it was only the magnet that was damaged from that encounter! I've seen magnets come up every now and again on the Facebook page "I Love Suzuki SV1000". The person sells them through the website https://www.mad8v.com/. Give them a message and see how you go. Hope that helps
YellowRider is offline  
post #14 of 18 (permalink) Old 22nd May 2020, 01:33 AM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
Quick update! Mad8v had a magnet, got it shipped super quick, and it's in! In an attempt to add value to the forum, I'll document my process as best I can.

My assumption that the cracked magnet couldn't be used may have been incorrect. After checking with a reference magnet that came out of the hub, the repaired magnet has the same poles! This will be a spare. Pictures attached, red arrow pointing "into" the bike when on the hub. I had been concerned that I wouldn't be able to determine the direction of the replacement magnet, but between the epoxy on inside surface and the compass, it wasn't an issue.

Filed and sanded the old epoxy off the magnets and rotors, cleaned both with degreaser and contact cleaner (as other posts detail) and made a little spacer helper, two and a half popsicle sticks, roughly 5.3mm. Helped me to make sure the spacing between was even when re-seating.

Went with a smooth & even layer of JBWeld on the back, and after clamping there was no oozing around the outside, which was promising. A quick measurement showed there was little to no increase in height.
Attached Images
File Type: jpg IMG_0529.jpg (538.8 KB, 12 views)
File Type: jpg IMG_0526.jpg (536.8 KB, 9 views)
File Type: jpg IMG_0545.jpg (565.3 KB, 8 views)
File Type: jpg IMG_0537.jpg (563.9 KB, 8 views)
File Type: jpg IMG_0541.jpg (513.4 KB, 9 views)
gregmontalbano is offline  
post #15 of 18 (permalink) Old 22nd May 2020, 01:42 AM Thread Starter
L-Plate Rider
 
Join Date: Jul 2014
 ♂ United States
New Jersey
Posts: 14
Garage
First two pictures showing OEM height vs repaired height.

Spacing between turned out more accurate than expected. I'm not sure the popsicle shims I fashioned were necessary, but they were a nice aid.

Next step is some JBWeld SteelStick in between mags, and bolt it all back together! Thank you to everyone here for their help!
Attached Images
File Type: jpg IMG_0553.jpg (519.9 KB, 10 views)
File Type: jpg IMG_0550.jpg (522.9 KB, 10 views)
File Type: jpg IMG_0558.jpg (521.2 KB, 10 views)
File Type: jpg IMG_0549.jpg (529.9 KB, 10 views)
File Type: jpg IMG_0567.jpg (568.1 KB, 11 views)
gregmontalbano is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the SV1000 Portal forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes Rate This Thread
Linear Mode Linear Mode
Rate This Thread:



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is Off
HTML code is On
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome