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 employ a wrench or socket to remove it. If that’s not possible, you can cut a slot into the bolt using a hacksaw, being careful not to cut too deep. Once the slot is made, use a vibration screwdriver to extract the bolt. Alternatively, you can hammer in a slightly smaller sleeve (like replacing a 19mm with an 18mm) so it fits securely into the bolt. This method works well for bolts from various manufacturers—Yamaha series bolts are typically black, Kawasaki ones are black or yellow, while Honda series are black, and Suzuki series are orange or orange/black.
In a six-wire system, each wire has a specific function. When replacing the rectifier regulator, make sure you match the wires correctly based on their color and function. For example, the Honda series uses a black wire for the ground, while Yamaha uses a green wire for identification. If the permanent magnet AC generator’s rectifier regulator is damaged, you can temporarily replace it with a single-phase full-wave rectifier, but this will reduce the efficiency of the three-phase AC power supply. Electromagnetic three-phase regulators are commonly used in large-displacement motorcycles because they offer better performance and easier voltage regulation. Some advanced models even include integrated electronic regulators inside the generator itself.
Most motorcycles use iron-type electromagnetic generators, and the standard six-wire three-phase rectifier regulators are widely used. The two AC input lines, one DC positive output, one DC negative ground, and one excitation coil line are all connected accordingly. 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 safely replace them. The colors for AC inputs, DC outputs, and voltage regulator lines are similar across different types, but be cautious not to mix up the excitation coil wire. For example, Honda uses a white wire, and Yamaha uses a green wire for the excitation coil. Always double-check the wiring before starting the engine to avoid any issues. If the casing becomes overheated, take appropriate action based on the situation.
Common methods for removing broken bolts include the surfacing technique. First, choose the right electrode size and current, then weld the broken area. After welding, shape it into a small cylinder about 5 mm above the surface, and weld a nut over it. Let it cool slightly, then gently tap and turn it out. This method works best for shallow breaks and requires skill to avoid damaging the workpiece. Another method is drilling: if the break is deep, drill a hole in the center of the broken thread using progressively larger bits. Then, use a square pyramid bit to tap and rotate out the broken piece. Be careful during this process, as mistakes can damage the internal threads, requiring re-tapping and causing more hassle.
When assembling threaded fasteners, tighten them gradually and evenly, using cross-assembly techniques. Pay attention to the torque specifications for different components. For non-critical parts, you can estimate torque by feel, but for important fasteners, use a torque wrench. For key-threaded connections, check the angle of tightening. Professional mechanics should always have torque-measuring tools and know the correct parameters. Damaged threads are generally not reusable. On scooters, many areas use self-tapping screws that tend to strip after repeated removals. In such cases, you can cut a piece of metal (iron or aluminum) to match the original shape, drill a slightly smaller hole, and reinsert the screw. This method can restore the connection effectively.
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