Denso Alternator, how to fit mechanically
Posted: Sun Apr 02, 2023 7:58 am
Hi everyone,
Long time no see... I am now in the process of rebuilding a dismantled CBX -79. As the OEM alternator have a toasted rotor, i will not waste time and money trying to fix it. Instead I will do what many of you alreade have done- install a Denso alternator from a Kawasaki ZX-9R -94 that I bought years ago. I have read many of the alternator conversion threads here but so far not found enough info how to DIY mechanically from scratch (not only buy a kit from TIM's or similar). A question about my photo attachments below: They are all rotated 90 deg. anti clock wise. Why is that?
This is the alternator I have The first problem to solve is to make the drive hub to fit the CBX shafts splines. Lyckily the Denso splines have a major diameter that is the same as the OEM splines' minor diameter. I have a friend that runs a wire electro cutting business. We copied the OEM splines and re-cut the Denso hub. Result! The Denso hub now slides snugly onto the CBX 19-spline shaft.
This is the modified Denso hub that now fit the CBX drive shaft
OK, now the hub slides on perfectly but does not reach the drive shafts 25 mm shoulder since it hits a corner in the crank case.
I had to make a spacer sleeve with OD=25.00mm, ID=20.00mm and L=12.00mm and slide it on against the drive shafts 25mm shoulder prior to fitting the Denso Drive hub. The Denso drive hub with L=12.0mm spacer sleeve under it in situ. Now there is some space between the hub and crank case Next, I have to order new Denso rubber cushions and install them between the Denso drive hub and the alternators driven hub.
Then when I push the alternator onto the drive hub, I can measure the gap between the alternator and crank case. The reulting measure will determine the thickness of the adaptor plate I need to make between the Denso alterntor and the CBX crank case. I own a one-man CNC-shop, so I can make lots of CNC-machined parts in house.
I have a question about this adapter plate: When you fit those ready made kits onto the crank case, do you feel that you squeeze the rubber cushions somewhat or is there some axial end play?
/ Peter
Long time no see... I am now in the process of rebuilding a dismantled CBX -79. As the OEM alternator have a toasted rotor, i will not waste time and money trying to fix it. Instead I will do what many of you alreade have done- install a Denso alternator from a Kawasaki ZX-9R -94 that I bought years ago. I have read many of the alternator conversion threads here but so far not found enough info how to DIY mechanically from scratch (not only buy a kit from TIM's or similar). A question about my photo attachments below: They are all rotated 90 deg. anti clock wise. Why is that?
This is the alternator I have The first problem to solve is to make the drive hub to fit the CBX shafts splines. Lyckily the Denso splines have a major diameter that is the same as the OEM splines' minor diameter. I have a friend that runs a wire electro cutting business. We copied the OEM splines and re-cut the Denso hub. Result! The Denso hub now slides snugly onto the CBX 19-spline shaft.
This is the modified Denso hub that now fit the CBX drive shaft
OK, now the hub slides on perfectly but does not reach the drive shafts 25 mm shoulder since it hits a corner in the crank case.
I had to make a spacer sleeve with OD=25.00mm, ID=20.00mm and L=12.00mm and slide it on against the drive shafts 25mm shoulder prior to fitting the Denso Drive hub. The Denso drive hub with L=12.0mm spacer sleeve under it in situ. Now there is some space between the hub and crank case Next, I have to order new Denso rubber cushions and install them between the Denso drive hub and the alternators driven hub.
Then when I push the alternator onto the drive hub, I can measure the gap between the alternator and crank case. The reulting measure will determine the thickness of the adaptor plate I need to make between the Denso alterntor and the CBX crank case. I own a one-man CNC-shop, so I can make lots of CNC-machined parts in house.
I have a question about this adapter plate: When you fit those ready made kits onto the crank case, do you feel that you squeeze the rubber cushions somewhat or is there some axial end play?
/ Peter