How to remove Alternator Cover

Trall · November 21, 2016, 17:20:09 PM

Quote from: bambam0099 on November 21, 2016, 10:15:44 AM
Glad you figured it out and thanks for letting us all know how to do this in case the situation ever happens to us.

Curious, didn't you notice a huge degradation of power if running only on one cylinder?

My mechanic friend said it could cause engine damage if I were to drive it far and at speed. Idk if that true since some trucks shut down some cylinders at highway speed to save on gas.

I was not driving it. Just starting it occasionally after I tried some repairs or checking connections before I took it to the Dealer. When idling though it sounded pretty good on one cylinder but again you could tell by the front exhaust pipe being cold and know not drive it.

bambam0099 · November 21, 2016, 10:15:44 AM

Quote from: Trall on October 26, 2016, 00:54:02 AM
...
That also made the bike run on one cylinder. A fast and easy way to tell is checking your two exhaust pipes, if one is hot and one is cold then your bike is only running on one cylinder not two as it should.

Glad you figured it out and thanks for letting us all know how to do this in case the situation ever happens to us.

Curious, didn't you notice a huge degradation of power if running only on one cylinder?

RockinRollin · November 10, 2016, 09:37:19 AM

This is all good stuff to know.

Trall · October 26, 2016, 00:54:02 AM

It's a little after midnight and everything reinstalled. I used a light skim coat of red RTV on both sides of the new gasket just for good measure and no oil leaks. The pickup coils #1 and #2 come as a set when purchased. I used as manual as it states to use silicone sealant on the rubber electrical coil and alternator boots that fit in a notch on the cover.

So my bike is all put back together but the silicone directions say wait 24 hours for maximum cure. So at least it all finally done and once cured, the only thing I have left to do is add 4 qts of oil and new oil filter and hopefully its ready for the road again..........I hope so.....I'll know Thursday morning.

Its a strange engine code to get with the FI light saying pickup coil #1 bad. That also made the bike run on one cylinder. A fast and easy way to tell is checking your two exhaust pipes, if one is hot and one is cold then your bike is only running on one cylinder not two as it should.

Trall · October 25, 2016, 20:17:56 PM

Thx. Did not use heat. I just got back from Menards and bought two small 8 in pry / nail remover bars $5.99 each. So I just put it on the lower tabs and it popped right off. I did not need two small pry bars, one did the trick instantly to each side tab. The small pry bar fit under the cover tab well for leverage and popped off in seconds. Their are two dowels or guide pins built into inside of cover, so that should help setting it back into its place.. The two coil packs are are the inside of the cover are in place by allen head and Philip head screws.

Thanks All......

Old Drifter · October 25, 2016, 19:02:31 PM

Anthony, I found this. I don't know if this will help. http://www.vulcanforums.com/forums/18-engine-work/72466-vulcan-classic-vn1500-stator-replacement.html#/topics/72466?_k=p56588

Trall · October 25, 2016, 18:47:24 PM

Quote from: Pilgrim on October 25, 2016, 16:25:27 PM
my service manual says remove bolts (shows 7) and then remove cover. Does say to replace the gasket and put silcone sealant where the two wire harnesses exit the cover.

Yes that's all my book says and of course the torque for reinstalling bolts but my darn cover won't come off is my issue. My 2001 has 8 bolts total to remove.

Iam thinking the two lower tabs are for prying it out and maybe there are the dowel / guide pins in that area but no luck moving it yet.

Iam trying heat when I get back home.

Pilgrim · October 25, 2016, 16:25:27 PM

my service manual says remove bolts (shows 7) and then remove cover. Does say to replace the gasket and put silcone sealant where the two wire harnesses exit the cover.

Trall · October 25, 2016, 15:47:59 PM

Ok. What a pain in the neck. Ill try again with the pry marks and try and break the gasket seal and maybe add some heat away from the electrical wires......Thx

Troll · October 25, 2016, 14:49:05 PM

Just looked at my manual...not very useful. I believe there are pry points, but I've never needed to go inside mine.

Trall · October 25, 2016, 14:01:47 PM

The left side foot shifter gear runs through this cover so I need to be carfull.

Trall · October 25, 2016, 13:58:12 PM

There are two metal tabs one on left and right sides lower that appear to be prying tabs. I tried a pry bar but no luck. Hit a little harder with mallet and not budgeing.

Would using a plumbers torch hurt anything?

Troll are you out there? Anyone know exactly what to do to get the cover off???

Trall · October 25, 2016, 11:46:17 AM

The round looking cover is the alternator cover. I disconnected the coil electrical and alternator electrical plugs.

Trall · October 25, 2016, 11:43:19 AM

Ok my pickup coil parts came last night. My mechanic friend bailed on me today something came up.

So Iam trying to install the new pick up coils today but cannot get the alternator / outer stator assembly cover removed. I manual only say remove cover but does not say how to. I tried gently tapping with a rubber mallet and not budging. All bolts were removed I triple checked. I drew a picture on the bolt pattern on cardboard and placed the bolts through the cardboard for their exact location.

Does anyone know how to remove it. It's under the left side cover.

Here's a picture.