[Corsica13]

You mean the rotor cover ? Or the rotor bolt ?

The cover bolts are just good and firm.....and you can clean the gasket as long as you are careful removing it and coat it in gasket cement (non hardening)
I have used the same gasket 4 times now that way....

Hi,
Thanks for the response, wow 4 times, why so many?
Yes the magneto cover / rotor cover.
Actually torque specs for both would be good, cover bolts and rotor bolt - would you know where I can find these?
I have also ordered a new gasket ready for when I decide to open the cover, I was advised that no glue or sealant is needed, apparently the gasket is enough.
Thanks again.

 

[schmidt314]

Hi,
Thanks for the response, wow 4 times, why so many?
Yes the magneto cover / rotor cover.
Actually torque specs for both would be good, cover bolts and rotor bolt - would you know where I can find these?
I have also ordered a new gasket ready for when I decide to open the cover, I was advised that no glue or sealant is needed, apparently the gasket is enough.
Thanks again.

These values are available in the service manual.

-ms

 

[Corsica13]

These values are available in the service manual.

-ms

Thanks buddy - do you have a pdf copy or a link to where I can get it please?

 

[Marty Moose]

Yep 2005 model 13km's one magnet moved. Stuck it on with shaft fit Loctite 609. Then as per usual JB weld between the magnets.

 

[muzza1000]

First I have to say Thank You to all the guys that have posted there experiences on the forum giving me the confidence to check and then tackle the solution to the Gen magnet issue.

My bike is a 2005 SV1000n with just over 25000 klms, yes you read it right.

Overserviced with synthetic oils all it's life.

Took the magneto cover off to inspect and found 2 magnets sitting on the coils and one moved.

Followed the repair procedure on this forum to the best of my ability. See following pictures.

2 magnets attatched on coils as I removed cover and 1 had shuffled around on rotor

See 1 magnet rotated against others

Rotar removed with quick rattle on removal tool

Rotor cleaned with contact cleaner, removed any residue and roughed up, reglued 3 loose magnets and also added fillets between remaining magnets. Difficult working with expoxy between magnets.

Masked up ready for epoxy between magnets

Back together and voltage checks and 1000 klms later no issues.

 

[Missing Link]

Nice set of pics..... good catch.... some will say to fill the gaps totally, but i think that 25% is enough, its basically a wheel chock

 

[muzza1000]

Nice set of pics..... good catch.... some will say to fill the gaps totally, but i think that 25% is enough, its basically a wheel chock

Inspection prompted by a different vibration coming through the seat on my favourite road Macquarie Pass to Robertson Pie Shop.

Yes I was pretty happy I checked then no damage at all, now the bike is also smooth.

 

[Missing Link]

Inspection prompted by a different vibration coming through the seat on my favourite road Macquarie Pass to Robertson Pie Shop.

Yes I was pretty happy I checked then no damage at all, now the bike is also smooth.

Mac Pass, now thats a road i havent visited in a very long time....remember the old man deciding to do that run back in the late 70's with a caravan behind the HQ wagon....in the dark toward the coast..... decided upon reflection to stop at i think the Mt Murray Rd intersection.....bit of a pull off there....camped the night...then the tippers started....all night HA HA....
The run down the hill was not fun back then in a low tech car with no electric brakes on the van....

 

[muzza1000]

Yep spot on Mt Murray turn off, bit of a gravel pit truck pull off. Definitely challenging under those circumstances but a great bike road with good surface and local knowledge it's a blast but a lot of people come unstuck.

 

[VeeTee]

Hello first post here, what a better presentation
SV1000S 2005, 30K Km, no idea about the oil as I bought it a couple of months ago.
2 broken magnets, 1 free to move, 3 shifted.
I recognized the problem as my bike was not able to charge my phone while riding and later I found the battery was getting weak in voltage.

 

[Missing Link]

Doesnt look like you have lost much magnet material, a good clean up of the crumbles and making sure that you have the poles correct when re- fixing
and it may very well be ok. BUt the stator on the other hand may be a bit messy. Do the proper checks on the stator continuity before reassenmbly and then the AC voltages
when running...

 

[mimixtz]

SV 1000S, 2003, 70.000 km.
THANK YOU ALL!!!
I heard about this issue.
This topic persuaded me that this is not IF, but WHEN.
I have spoken with both previous owners of the bike, they both took care of this bike nice, and none of them was aware of this problem.
I said to myself, well, I'm probably lucky, I have non-affected one, everything works perfectly, charging is great, why bother.
Then I joined to this forum and saw SO MANY reported problems and pictures...
Then I realized that this is really just waiting for disaster to happen.
I ordered JB Weld, flywheel puller and new gasket. I said to myself, well, even if all magnets are in place holding up good, I'll fill the gaps with JBWeld. And I opened the case.
Here is the result, magnets all in 1 piece, I could pull out 3 of them instantly, stator intact.
charging was still good.
Now I have some work to do: removing flywheel, baking the flywheel to be able to remove all magnets, sanding, cleaning, gluing, filling, more sanding, putting it back together.
Luckily, we have snow and it is cold, so ideal time to do that.

 

[Missing Link]

Here is the result, magnets all in 1 piece, I could pull out 3 of them instantly, stator intact.
charging was still good.
Now I have some work to do: removing flywheel, baking the flywheel to be able to remove all magnets, sanding, cleaning, gluing, filling, more sanding, putting it back together.
Luckily, we have snow and it is cold, so ideal time to do that.

Well done..... there is no need to remove the other magnets if they are still stuck....
Just make sure when you put the loose ones back that you make sure the magnetic poles are correct. Otherwise it will effect the charging rate.
Correctly positioned they should try to grab each other.
A very fine even smear of JB on the magnets to hold them in place, and then fill between. It is the "shearing" force that the gap filling stops.

 

[mimixtz]

Thanks, I know about N and S poles yes. I can't remove the flywheel no matter what I do. Torquing the puller, heating,... Puller is now torqued and I'll leave it during the night. Maybe it will pop off tomorrow. The other 3 are glued really well. I couldn't remove them even after heating them with a torch. My idea was to remove the flywheel, put it in the Owen to be able to remove the other 3 magnets, sand everything, degrease everything and do the JBWeld part on the bench. If I won't be able to remove the flywheel tomorrow, I'll leave remaining magnets on, sand and degrease everything and do the JBWeld part with flywheel on the bike. Not very convinient, but what can I do if that thing doesn't want to pop off... 😐😑😉🙂

 

[estevns]

Thanks, I know about N and S poles yes. I can't remove the flywheel no matter what I do. Torquing the puller, heating,... Puller is now torqued and I'll leave it during the night. Maybe it will pop off tomorrow. The other 3 are glued really well. I couldn't remove them even after heating them with a torch. My idea was to remove the flywheel, put it in the Owen to be able to remove the other 3 magnets, sand everything, degrease everything and do the JBWeld part on the bench. If I won't be able to remove the flywheel tomorrow, I'll leave remaining magnets on, sand and degrease everything and do the JBWeld part with flywheel on the bike. Not very convinient, but what can I do if that thing doesn't want to pop off... 😐😑😉🙂

Some flywheels pop off quite easily with the flywheel puller while others takes quite a lot of patience. Give it a few hits with the impact gun, leave it overnight, repeat until loose.

First time gluing magnets I did it in situ - however you it takes some covering up the rest of engine so brake cleaner and grinding dust don't go everywhere.

 

[mimixtz]

Well, I was heating it, hitting with BIG impact gun, trying that for 2 days... Nothing. I had a feeling that I'm destroying puller threads. And yes, I barely get it out. So I stopped.
Plan B: to unglue all magnets and do everytning with flywheel on the bike.
Started to try to unglue the rest of the magnets. Heating them, carefully prime them with flat pieces of wood, all wood pieces broke, plastic prime tools had no effect either, didn't even bother using them since they would melt, tried carefully with round shaped flat screw driver. No way. I chipped one. So I stopped.
Plan C:
Leave 3 magnets on, protect everything, sanding, vacuuming, cleaning, repeat...
And this is the situation now.
With addition that I filled JB Weld in all gaps using syringe after 4-5 hours when basic JB Weld already cured a little bit.

 

[Missing Link]

Stuck on tight thats for sure....

I hope you unscrewed the spacer bolts from the JB before it set........

 

[mimixtz]

Yes, I did.
Giving it another day to cure since layer of JBWeld between magnets is thick.
I used opportunity and cleaned all mess around front chain sprocket and inside front chain sprocket cover which was collecting there for the last 20 years.
Today (if I had time) or tomorrow or during weekend I have some sanding and cleaning to do.
I'll use dremel with sand paper bit and slow speed and holding vacuum cleaner hose next to it.
If anyone has better idea, I'm all ears.
And after that, putting it back together.
Weather is really bad 💨☔❄⛄ so no need to hurry.

 

[Missing Link]

If you are referring to sanding the JB with the Dremel, then make sure you try to make all the JB the same height, just to try keep the weights the same for balance.
Yeah, i know its being a bit picky, but details help...

 

[mimixtz]

Of course, that is self-understanding to me.
On the other hand, since bike was running great despite 3 magnets being moved / bunched together, there is no way I could make it worse, only better.
Which I probably won't feel.