When removing a hex head bolt that has a stripped edge, you can follow these steps: first, use a trowel to repair the damaged area and then secure it with a wrench. Alternatively, use a hacksaw to carefully cut a slot into the bolt without going too deep. Once the slot is made, use a vibrating screwdriver to remove the bolt. Another option is to use a slightly smaller socket (e.g., 18mm instead of 19mm) and gently hammer it onto the bolt. This method works well for bolts from brands like Honda, Yamaha, or Kawasaki. For example, in a six-wire system, Honda typically uses black wires, Suzuki uses orange or orange/black, while Yamaha and Kawasaki use brown. When replacing, ensure you match the function of each wire correctly. If the rectifier regulator of a permanent magnet AC generator is damaged, you can temporarily use a single-phase full-wave rectifier as a replacement. However, this will result in underutilization of the three-phase AC power from the engine. On the other hand, electromagnetic three-phase rectifier regulators are commonly used on large-displacement motorcycles, offering better efficiency and easier voltage regulation. Some advanced models even integrate electronic regulators within the generator itself. Most motorcycles still use iron-type electromagnetic generators, and the standard setup is a six-wire three-phase rectifier. Two wires are for AC input, one is DC positive, one is negative ground, and the last connects to the engine. The excitation coil adjusts current based on output voltage to stabilize the system. As long as you understand the function of each wire, you can make the correct connections. The colors of the two-phase AC input lines, DC output lines, and the voltage regulator line are similar to those found in permanent magnet systems. The only thing to watch out for is the excitation coil wire—on Honda it's white, and on Yamaha, it's green. Always double-check your wiring before starting the engine. If any issues arise, such as overheating, take appropriate action depending on the situation.
Common methods for dealing with broken bolts include the surfacing technique. First, choose the right electrode size and current setting, then weld over the break. After welding, shape the area into a cylindrical form, about 5 mm above the surface, and weld a nut over it. Let it cool slightly, then tap gently and spin it out. Be careful not to damage the workpiece, as this requires skill. This method is best for shallow breaks. Another approach is the drilling method, which is suitable when the break is deep inside the material. Start by drilling a small hole in the center of the broken thread, gradually increasing the drill bit size. Ream slowly until you reach the broken part, then use a square pyramid tool to extract the fragment. However, if you make a mistake during drilling, you risk damaging the internal threads, requiring re-tapping and causing more hassle. Therefore, this method should be done with caution.
When assembling, start by tightening the bolts and nuts using the proper sequence. For cross-assembly, always consider the torque requirements of different fasteners. For general fasteners, torque can be estimated by feel, but for critical ones, use a torque wrench. For key thread fasteners, check with the angle method. Professional mechanics must have torque-measuring tools and know the correct usage and associated parameters. Also, damaged threaded fasteners should not be reused. Many scooters use self-tapping screws, which can strip after repeated removals. In such cases, cut a piece of metal (like iron or aluminum) to match the original shape, drill a slightly smaller hole than the screw diameter, and then re-tighten the self-tapping screws. This will restore the connection effectively.
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