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Ganeral Maintenance Alert / Alternator Brushes.

Discussion in 'XJ Technical Chat' started by RickCoMatic, Sep 5, 2006.

  1. RickCoMatic

    RickCoMatic Well-Known Member

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    There has been a spike in maintenance issues related to the contact brushes for BOTH Alternator and Start Motor on this forum and others.

    If you haven't checked the operating limit of your Alternator Brushes in some time; you should perform this very simple inspection at your earliest convenience.

    Remove alternator cover. 3-Screws on the round case cover to immediate left of starter motor.
    Shine some light on the 2 contact brushes in their holder on the reverse side of the alternator cover.
    Look for "The Line" etched into the side of the brush; its wear bar. (Similar to wear bar on tire.)

    Wear close to indicator or indicator no longer visible. Replace brushes; soon.
     
    RickCoMatic, Sep 5, 2006
    #1
  2. Flatwound

    Flatwound Member

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    RickO-
    I am about to order brushes for my 750 Max- I assume there are 2 brushes in the alternator- correct??
    Bill
     
    Flatwound, Sep 5, 2006
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  3. RickCoMatic

    RickCoMatic Well-Known Member

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    Yes ...

    2-Small brushes -- nearly square; but in reality rectangular, in their mounting assembly mounted inside the alternator cover.

    The alternator brush mount is secured to the cover by a pair of cross-head screws for ease of service.

    Alternator Brush specifications -- XJ-Series Bikes (excluding XJ900RK)>
    New = 17mm (0.67in.)
    Service limit = 10mm (0.39in.)

    Starter Motor Brush specifications
    New = 12mm (0.47in.)
    Service Limit = 8.5mm (0.33in.)

    Disconnect Battery before beginning work on electrical system components.
     
    RickCoMatic, Sep 5, 2006
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  4. Blackhammer

    Blackhammer Member

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    Rick,

    BTW, the new brushes that I recently got from Oldbikebarn did NOT have any wear indicators on them. I measured them with calipers to verify their size. And you are on the money with those specs. My XJ750J Yamaha service manual lists those specs.
     
    Blackhammer, Sep 5, 2006
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