Buttoned up the Primary Mishap (sounds like a punk/metal band
) last night and made a successful test run with almost no issues. It appears I was able to save the alternator somehow. I used automotive grade black epoxy (you guys
WISH you had access to this epoxy, freaking fantastic stuff
) to refill all the areas where the epoxy on the alternator had cooked and broken off. I also recoated the entire inner surface with epoxy and smoothed it out with a small drum sander until the rotor and alternator had a good fit. I reinstalled the rotor with everything else off and ran the motor to examine the trueness of the rotor. It appeared to be correct, much better than it was anyways. Then while the bike was running, I held 180 grit paper to the rotor as I sprayed brake cleaner on it. This removed all the crap that had glued itself to the rotor, it also looked like it was removing a small amount of metal, so I kept sanding for a bit longer to try and get a bit more clearance. All said and done, I ended up with a .007 gap, which to me still seems a bit too tight, but we'll see.
I went a bit different on the reinstallation of the outer primary cover. I wanted to make sure that this punk beeotch didn't leak again, so I removed the center mounting stud and went down to Ace Hardware. I was able to determine that a 3/8"x26 Witworth is just a smidge smaller diameter than than a 10mmx1.0 bolt but have a nearly identical thread pitch. So I got a 10mmx1.0 bolt about 1/4" longer than the stud I had. Went back to the garage and went to work. As it turns out, the 10mmx1.0 was a real tight but I could get the first 2 threads started. I was skeptical but determined to make this work, so I removed the bolt, sprayed a BUNCH of Liquid Wrench into the threads, started the bolt again and started forcing the bolt in with my cordless impact. Guess what? I ended up with a primary cover with a locking thread bolt!
Now, I'll admit it was a PITA getting the bolt lined up with the clutch arm and what not, but I made it work. I also ran a bead of Ultra Black silicone on the bottom half of the primary cover and let it dry overnight. Went out there after work last night, filled her back up with some Type F ATF. Now it's only leaking from the clutch shaft seal and I'm not too worried about that. My problem is that now that I have the correct amount of fluid in the primary, my clutch is slipping like a mofo again.
Oh well, at least I can ride again. And for the record, you probably won't be able to do this mod without an impact wrench. You'd be there a LONG time with a ratchet.
Scottie