Question about Harley Davidson XLH 1000 Sportster Motorcycles

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Generator wiring schematic

The holes where the bolts go to hold the generator are stripped how can I fix this

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You can buy a Helicoil kit from MSC Direct. It is a pretty major operation for a beginner, but not impossible. Since I do not know your level of mechanical aptitude, I can not say if you can do this yourself. I've done it many times, and if you have a "standard" repair, it's easy. It's the special ones that require longer thread engagement, that are tricky. You will have to drill and re-tap the holes using the tap provided in the kit, and then screw in the thread inserts. Some of the inserts have a tang that can be snapped off, if you need to have a long threaded hole. Again, this is not usually done by a beginner. If you are not familiar with mechanical assembly and repair operations, take it to a shop and have it done.

Turbocouch

Posted on Dec 30, 2013

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Posted on Jan 02, 2017

DickCanFixIt
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SOURCE: stripped seat mount

Use a Helicoil or a Recoil. Either is available at your local auto parts or search the 'net for "thread repair" and you'll find what you need. It will take a drill bit and a tap or two, but the hole will be as good as new when you are done.

Posted on Feb 15, 2009

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I have a Polaris 280 and one of the two screws that holds one of the wheels on is stripped.


You are referring to the wheel axle. The axle is held together to the vac sweeps base, with two bolts and nuts. What you can do, is remove the stripped one, going thru to get another new STAINLESS STEEL, bolt with a matching nut, and tighten it from the bottom. You will need to get access to the bottom, by removing bottom cover - two fasteners hold that.
Don't be intimidated, it doesn't matter what you use - a bolt or ???, you just want to secure the axle to the base. I would recommend a bolt and nut.
I added a link below, to show a diagram of the unit all taken apart.
Area of significance: Parts 13-16 The nuts, are recessed in a small Divet in the bottom of the middle bass.
Vac Sweep 280

Apr 14, 2015 | Pool & Spa

1 Answer

How to remove and replace the stator from a champion generator


You don't state what model you have. I just replaced the rotor on a Champion Model 41302 but removing the stator is the same process.

You will need to remove the muffler and muffler outer protection. Remove the bolts that hold the muffler outer protection. Remove the two bolts that hold muffler to the engine exhaust.

Take a block of wood and place it under the engine to support the generator. The supports on the generator head end will be removed so the generator will tip down and make it difficult to remove the stator.

Remove the generator end cover by removing two bolts.

Remove the two bolts that hold the muffler to the end cover.0834b898-460f-41f6-b0a0-6704ae605277.jpg

Remove the bolt that holds the ground from the generator to the frame.

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Remove the two bolts that hold the end cover supports to the rubber supports to the frame.

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Disconnect the quick connect electrical connectors and remove the 120/240 volt wiring from the terminal block. See second picture below.


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Remove the ground from generator to wiring cable assembly by removing the bolt that connects it to the end cover. Yellow and green wire in picture above.

Remove the bolt from DC brush assembly and pull out of generator. Picture below shows assembly removed.

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The stator and cover now can be removed from the generator. Take a rubber mallet to tap on the back of the brackets on the end cover to loosen it. The rotor bearing is seated in the end cover making it hard to remove by pulling by hand. Once lose pull straight out.

The stator can now be removed from the generator end by taking the four bolts out.

The installation process is the reverse.

Nov 27, 2013 | Electrical Supplies

1 Answer

How do I separate the engine from the generator? I removed the 4 bolts holding the flywheel housing and the long bot thru the center.


If you are trying to remove the power head from the engine tip the engine side down so the recoil is at ground level. Place some rags between the engine and the generator. Locate or obtain a bolt that is snug in the hole of the generator at least 4 inches long with a nut and a big fat washer. Spin the nut up about 8 or 9 threads and start wrapping the bolt with teflon pipe tape. I am talking about making a HUGE bulge of teflon tap just past the first thread almost to the washer. You will be using the teflon to grip the end of the rotor and act like a threaded insert. Fill the hole that you removed the long bolt from with oil all the way to the hole opening. Start threading the bolt into the hole and use the nut to keep the washer flat against the end of the rotor and to keep the teflon from peeling off. After the bolt has passed into the hole about 2 inches it should separate the rotor from the engine. It will BANG when it pops loose and dump the oil you added onto the rags. I.e it will scare you! Then you can just lift it off.
I have done this so many times to repair generators that I have lost count. It works every time.

Thanks for choosing FixYa,
Kelly

Aug 26, 2011 | Northstar Generator 13 Hp, 8000 Watt,...

1 Answer

How to change the alternator on my 2000 grand voagear


This is for a 3.3L motor
Hope this helps, it it does please leave feedback and vote Thank You and Good Luck

REMOVAL

  1. Release hood latch and open hood.
Removal/Installation of Battery Cables 81929864

  1. Disconnect battery negative cable.
  2. Remove windshield wiper housing, refer to the Windshield Wipers and Washers for proper procedures.
  3. Remove accessory drive belt.
Generator Mounting Bracket 81929870

  1. Remove bolt holding top of generator mount bracket to engine air intake plenum.
  2. Remove bolts holding outside of generator mount bracket to generator mount plate.
  3. Remove bolt holding top of generator to mount bracket.
  4. Remove generator mount bracket from vehicle.
  5. Rotate generator toward rear dash panel.
Generator 81929868

  1. Disconnect the push-in field wire connector . from back of generator.
  2. Remove nut holding B+ wire terminal to back of generator.
  3. Separate B+ terminal from generator.
Generator Pivot Bolt 81929871

  1. Remove bolt holding bottom of generator to lower pivot bracket.
Generator 81929872

  1. Remove generator from vehicle
INSTALLATION

  1. Place generator in position on vehicle.
  2. Install bolt to hold bottom of generator to lower pivot bracket.
  3. Place B+ terminal in position on generator.
  4. Install nut to hold B+ wire terminal to back of generator.
  5. Connect the push-in field wire connector into back of generator.
  6. Rotate generator forward away from dash panel.
  7. Place generator mount bracket in position on vehicle.
  8. Install bolt to hold top of generator to mount bracket.
  9. Install bolts to hold outside of generator mount bracket to generator mount plate.
  10. Install bolt to hold top of generator mount bracket to engine air intake plenum.
  11. Install accessory drive belt.
  12. Install windshield wiper housing, refer to the Windshield Wipers and Washers for proper procedures.
  13. Connect battery negative cable.
  14. Verify generator charge rate.

Jan 02, 2011 | 2000 Plymouth Grand Voyager

1 Answer

Replace alternator in chrysler town and country minivan


REMOVAL
  1. Release hood latch and open hood.
  2. Disconnect battery negative cable.
  3. Disconnect the push-in field wire connector from back of generator.
  4. Remove nut holding B+ wire terminal to back of generator.
  5. Separate B+ terminal from generator.
  6. Raise vehicle and support.
  7. Remove the right front lower splash shield.
  8. Remove accessory drive belt, refer to the Cooling System for proper procedures.
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  1. Remove the lower oil dip stick tube bolt (Fig. 2).
  2. Remove wiring harness from the oil dip stick tube
  3. Remove the 3 mounting bolts.
  4. Lower vehicle.
  5. Remove oil dip stick tube from vehicle.
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  1. Roll and remove the generator from vehicle (Fig. 3).
INSTALLATION
  1. Roll and place generator in position on vehicle (Fig. 3).
  2. Install upper bolts to hold generator in place.
  3. Lubricate the O-ring. Install oil dip stick tube.
  4. Install the upper oil dip stick tube bolt.
  5. Place B+ terminal in position on generator.
  6. Install nut to hold B+ wire terminal to back of generator.
  7. Connect the push-in field wire connector into back of generator.
  8. Raise vehicle and support.
  9. Install the lower mounting bolt and tighten.
  10. Install the lower oil dip stick tube bolt and tighten (Fig. 2).
  11. Install accessory drive belt, refer to the Cooling System for proper procedures.
  12. Install the right front lower splash shield.
  13. Lower vehicle.
  14. Install wiring harness to the oil dip stick tube
  15. Connect battery negative cable.
  16. Verify generator output rate.

Dec 13, 2010 | 2001 Chrysler Town & Country

3 Answers

Remove motor from generator


aramature must be removed to get to the mounting plate it will slide out off case loosen long bolt in center of armature hold armature and hit bolt briskley will pop off be careful putting arm back may be 2 brushes inside have a helper hold brushes back

Jul 30, 2010 | Briggs & Stratton Briggs and Stratton...

1 Answer

It wll not start. will run with starting fluid. cleaned carbueator out . ithink i need a new carb. where can i get one


cleaning the carb requires that you ALSO take a very fine wire and push it through the tiny hole in the BOTTOM of the bolt that holds the float bowl in place. That tiny orifice is what gets blocked when the generator sits for a time and the only way to clean it is with very tiny straight pin or a wire. It won't run without that hole being opened up.

Jul 24, 2010 | Coleman Powermate Premium Plus 6250W...

1 Answer

Have crafsman 5500generac generator need to seperate genhead from


Remove all wiring. Remove four stator bolts. Remove stator. remove rotor through bolt tap end of rotor us a shaft in the rotor tighten bolt in tapped hole to remove rotor.

Mar 25, 2009 | Watts Onan Portable Generator - 4000 ,...

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