Well, I suffered the typical seized alternator problem like so many other UK riders. I can't afford the money for a new one and I take offence at being expected to pay hundreds of pounds for an alternator which is so similar to ones which sell for around ?40 on eBay.
So a little research on the Internet showed that some people have used an alternator from a Bandit, but I couldn't find any real details.
I took the plunge and bought an alternator from a local breaker for ?40. He thinks it's from a Bandit, but can't be sure.
The replacement looked a lot like the ST alternator, except the drive shaft was different. Should be easy enough to change that I thought.
It wasn't until I looked a little closer that I realised that the front end was different too. But do you think I could change just the shaft and front end ?
That would have been too easy.
The Fixing screws are in a different location on the Bandit alternator... You know, the ones which hold the two halves together.
So, my only option left to me is to use the entire case of the bandit alternator with my original shaft.
The front of the bandit case is different and has a protruding collar around the oil seal so I ground that off (see picture) ..... I'll add pics later, my iPad doesn't allow adding pics to posts..
After a lot of struggling I managed to prize the two halves apart and proceede to install my shaft into the new case. As soon as I tightened the casings together everything went tight and the alternator wouldn't turn. I wrestled with this for a while and then gave up thinking I had done something wrong and buggered the whole thing up.
I tried to get a proper ST alternator for a reasonable price and failed so I decided to buy another Bandit one and give it another try.
?40 later and I was at it again, but this time I found the reason for the alternator jamming.
The shaft in relation to the rear bearing is slightly longer than the Bandit shaft and the back bearing was bottoming out when I tightened the cases together.
My opens at this point were to either get a lower profile bearing or try to machine about 2 or 3mm out of the back casing to allow the shaft to go fully home. Not really wanting to pursue either of these options I hit upon another idea - although it's a bit of a bodge, I think it will work out ok.
I inserted a couple of washers between the case halves so that the case tightens up, but there is a slight gap between the halves.
It's not a great solution, but the magnets are still between the coils and the alternator turns fine.
I don't think there will be any problems when I refit it as the bolts holding the alternator to the engine will keep the washers in place and there is an even clamping force around the whole unit.
I'll let you know how it goes in a couple of weeks when I get the bike back together. I am doing a full repaint at the same time so it could be a while.
Disclaimer- this is what I have done, you are responsible for anything you do on your bike .... If it doesn't work out for you then it's not my fault.
Keep your fingers crossed for me, if this works it has only cost me ?80 and it could cost you only ?40 if you are not daft enough to buy a second alternator when one would have sufficed..
So a little research on the Internet showed that some people have used an alternator from a Bandit, but I couldn't find any real details.
I took the plunge and bought an alternator from a local breaker for ?40. He thinks it's from a Bandit, but can't be sure.
The replacement looked a lot like the ST alternator, except the drive shaft was different. Should be easy enough to change that I thought.
It wasn't until I looked a little closer that I realised that the front end was different too. But do you think I could change just the shaft and front end ?
That would have been too easy.
The Fixing screws are in a different location on the Bandit alternator... You know, the ones which hold the two halves together.
So, my only option left to me is to use the entire case of the bandit alternator with my original shaft.
The front of the bandit case is different and has a protruding collar around the oil seal so I ground that off (see picture) ..... I'll add pics later, my iPad doesn't allow adding pics to posts..
After a lot of struggling I managed to prize the two halves apart and proceede to install my shaft into the new case. As soon as I tightened the casings together everything went tight and the alternator wouldn't turn. I wrestled with this for a while and then gave up thinking I had done something wrong and buggered the whole thing up.
I tried to get a proper ST alternator for a reasonable price and failed so I decided to buy another Bandit one and give it another try.
?40 later and I was at it again, but this time I found the reason for the alternator jamming.
The shaft in relation to the rear bearing is slightly longer than the Bandit shaft and the back bearing was bottoming out when I tightened the cases together.
My opens at this point were to either get a lower profile bearing or try to machine about 2 or 3mm out of the back casing to allow the shaft to go fully home. Not really wanting to pursue either of these options I hit upon another idea - although it's a bit of a bodge, I think it will work out ok.
I inserted a couple of washers between the case halves so that the case tightens up, but there is a slight gap between the halves.
It's not a great solution, but the magnets are still between the coils and the alternator turns fine.
I don't think there will be any problems when I refit it as the bolts holding the alternator to the engine will keep the washers in place and there is an even clamping force around the whole unit.
I'll let you know how it goes in a couple of weeks when I get the bike back together. I am doing a full repaint at the same time so it could be a while.
Disclaimer- this is what I have done, you are responsible for anything you do on your bike .... If it doesn't work out for you then it's not my fault.
Keep your fingers crossed for me, if this works it has only cost me ?80 and it could cost you only ?40 if you are not daft enough to buy a second alternator when one would have sufficed..
