While my 79FXS is on the jack for transmission and cam repairs, I figured I'd take a look at the alternator rotor and make sure the magnets were in place. The compensator shaft extension is badly worn, so I also want to replace it if I can find a good replacement part. It should have been an easy job, but the shaft extension is stuck on the crankshaft pretty tight. Is there a trick to removing it? I tried prying with a large screwdriver, but didn't want to break anything before asking here. Meanwhile I sprayed it with PB Blaster. Thanks, Joe

 

Since that is a 10B Sliding spline in the bore when not under load, obviously someone used red sleeve Loctite on it I think. You just may need a little heat. Go quick. Heat on the alternator rotor and you will need more than an inspection. Interesting sine your rotor is tapped for pulling. Maybe it and the extension are made interference. Mine only has holes for hooks. It also has spun and stripped. Dealer told me he replaced 1 a month with TCs.

I would probably stud over to the rotor and use it to pull it carefully. If you tweak it with a pry, it can pop those magnets off. I tride to chip out one just to get the magnet. I tried to use a screw driver and hit behind the glue. The magnet shattered. I tapped it on the outer OD of the cup.. They just popped off.

 

Thanks, Ripsaw, I tried heat but it didn't work, so I ground the flange on the extension shaft and used a 3-bolt puller on the rotor. I was pleasantly surprised to see the magnets were encapsulated in plastic. Is this a higher amp rotor, maybe EVO?




The splines on the shaft look good, but I lightly dressed them with a fine file. There is no evidence of loctite on them either. I cleaned the threads after I took the picture.



I already ordered an OEM shaft extension because the outer splines on this one are shot. But the inner ones are good. IDK why it was so tight. I hope the new one slides on easily.



The rotor slides on and off easily. Last time I had the primary off I marked the rotor so I had to make sure it went back the same way. I did add a little silver paint this time.



So I say I'm good to go, once the new part arrives.

 

is it worth changing the engine seal while its apart ?

 

why TDC paint mark

 

That is some heavy duty spline engagement and quality compared to a TC. The spline engagement on it is only as long as the thin shell of the rotor
The bean counters sure got their bonus for that change. Cost me 3 warranty copays and finally when out of warranty when I fixed it. Thanks Harley Davidson. Will be eating the free barbeque at the local Harley shop the rest of my life to break even.

 

I can't remember if the Ultima ignition is set by TDC, or I just did it because I could.