Motor: Rotor and Alternator

Installed the new rotor and alternator.  The alternator wires were cut, but other than that it looks ok.

Roxy: Charging System Test

Tested Roxy's voltage at idle with lights off and on.  Multimeter was attached to batter positive and ground to engine block.

At idle I was seeing 7.75 (and climbing).

With lights on I saw 6.85 volts (high and low beams measured the same).

Fabrication: Date with the Dremel

Tested the new cover for fit.  Not too far off, though certainly wasn't perfect.

The window alignment was spot on, but I'll need to widen it even beyond the red marks.

Again, just a bit off.

The top screw hole didn't line up perfectly once the other two were screwed in. 

A trip to the vice and a date with the Dremel.

Finally a good fit for all 3 holes.

Cleaned up the viewing window but plan to cut an even bigger one using a cutting wheel.

Fabrication: Alternator Cover with Timing Window

Did my first official "project" at Techshop, even though it was a quick 10-minute job.  The hydraulic shear was out of service, so I just cut the sides with the corner notcher.  Turret punch worked as expected, though I realized the punches don't have actual measurements on them, so you either have to know in advance or should punch some test holes on scrap if you need exact measurements.

Finally used the Beverly shear to cut out the circle, which worked fine, even though the cut was pretty ragged.

Next I'll need to clean up the cuts with the Dremel and test the actual fit.

Roxy: Not Elegant

Not a very elegant setup, but it'll do temporarily to stop the oil spray while I"m trying to do dynamic timing.

CM91: Alternator

Wanted to compare the alternator in the S90 with the one in the CM91, and realized that I'd never actually opened up the CM91's alternator cover.  There were 2 frozen screws, but they got re-slotted and one whack with the Lisle did the trick.

Stopped short of actually removing the alternator since I have to use the clutch tool to hold it in place so I can turn the bolt.

Worth noting, the CM91's alternator is stamped "CS90".  The S90's is stamped "CT90".

S90: Alternator

Fiddling with the wiring harness led me to the alternator and I decided to give removal a try.  The nine left crankcase screws came out easily with the impact driver.  I then used the clutch basket holder to lock everything in place so I could remove the flywheel bolt.

Next I got a chance to use the 14mm flywheel puller for the first time.  Using a good dollop from the new can of Moly-B grease, I used a 16mm wrench to tighten it into place (once again using the clutch basket holder to keep everything locked up).  It worked fine, except I noticed a lot of metal slivers coming off the puller.  Inspecting it, I saw that the threads were getting shaved.  But I went ahead and pulled the alternator out, then unscrewed the stator so I could get a look behind it.