Can't get alternator rotor out of 750 Maxim

I'm having a bit of difficulty getting my alternator rotor out. I didn't have the pin to stick in the hole so I just stuck a bolt in there. I proceeded to screw the rotor puller bolt in and before I realized it, the bolt was turning like it was stripping. I pulled the bolt out and sure enough, it messed up the threads pretty bad. Before the bolt started to cross thread, it looked like the rotor was coming out. I can still manage to get the rotor puller in the messed up threads about a half an inch but that's it, any ideas? Screwed for the moment...

 

get that bolt out of there and never put it back again
A: get the right size bolt and hope the threads aren't to messed up yet
B:get a tap for about 16$ fix the threads try again with the right bolt
C: check your alternator brushes and put that cover back on and never tell anyone what you did

 

In spite of the troubles, that is a great example of the cleanest XJ engine I have ever seen! Do clean freaks ever ride? Jealous I am, but damn I hate cleaning.

 

I had the correct rotor removal tool (picture 2), 16mmX1.5 thread but I didn't have the little pin that it bears down against the shaft. I ordered a 16mmX1.5 bottom tap but I don't know how much thread I'm going to be able to cut, it's pretty messed up. Hopefully enough to get the bugger out of there. I'm going to get a drill rod that fits inside the inner hole and cut it off. Should have done it with that to begin with but I thought a cut-off 1/4" bolt inside would suffice, but it bent, and that's what caused the the rotor tool to strip the rotor threads. I might have to tap for a larger bolt. Live & learn...story of my life! Any other thoughts?

I'll take that as a complement but honestly I haven't washed it in 12 years. It looks clean because it has been garaged it's entire life. In it's younger days, I did keep it clean. Do clean freaks ever ride? Well I guess the odometer tells the story... 30,000 miles and climbing by yours truly! Although the bulk of that mileage was the first 10 years of existence.

 

Oh wow, the rotor is mounted on a shaft. You've messed up the threads on the shaft right...not the rotor itself? Ouch, replacing the shaft is a bit more surgery. I'm assuming it's the same for your Maxim as my Maxim-X.

Assuming you can get the rotor off, is there a chance you could drill out the threads recessed in the shaft and insert a helicoil?

 

No the shaft is fine, I'm talking about the rotor threads that are messed up. There is a bolt that holds the rotor on the shaft and the extractor tool threads into the rotor to allow you to pull it off the shaft. Two different size threads. The shaft threads are fine... its the rotor threads that are messed up. Hopefully once I get the rotor off, and replace the seal, I won't need to take it off again. that's the whole reason I'm doing this to begin with.

 

I just used a 16mm x 1.5mm bolt, but I ground a tapered 'nose' on it, rotor popped right off.

 

You're right...it's been a while since I took mine out (also to repair the seal). I was getting an oil leak around the seal out the cover, then along the bike.

One further thought...a lesson learned for me. When you remove the shaft bearing to replace the seal (an o-ring),

1.) oil the shaft to make it slick.
2.) as you pull on the bearing, simultaneously push on the shaft. Otherwise the shaft will probably move with the bearing and dislodge. Once dislodged it's a bear to get realigned.