- Tue Dec 25, 2012 10:42 am
#21020
Something to mull over if Xmas is not your thing? And I wish my problem was as simple as the advice been given out here!
My Bullet has been very quiet recently! In fact, after getting the M.O.T/Tax done towards the end of September, my bike has hardly turned a wheel since. I thought I'd developed a charging problem and checked out most of the system with a test meter. The fairly old battery was replaced for less than £17 (from the re-vamped Hein Gerhicke chain, filled with acid with the bottle supplied). This went flat within a few weeks of local commuting use. More testing and I thought the regulator was shot, so that was replaced by a single unit, that actually replaces both the Indian Reg/Rec units. This was £25 from Henry at Price Part. Alas, still not enough volts getting to the battery. Headlight was getting feed from the Alternator, and one out of the two charging circuits was showing over 45v at speed, the second circuit was barely over 8-10v.
Time to take the primary cover off. Oh dear, what a mess (or words to that effect?). There are people here that just know what is coming next I'm sure? The large hexagonal nut on the Rotor dropped out with the oil, it's collar was sheared off and still on the crank. The large spring washer was attached to the bottom of the stator. The Rotor itself had shifted along the crank, causing said hexagonal to make plenty of contact with the outer primary cover, A lot of metal, shrapnel would be the best description, was in the oil ect.
Upon removal of the Stator, this revealed the full state of the Rotor, with no less than four of the six metal inserts missing/destroyed. A large chunk of one these inserts was actually embedded into one of the stator windings to a depth of some 1/4 inch or so!.
It took some persuasion with a three-legged puller to get the Rotor off. This revealed the woodruff key was sheared and there was quite a build up of excess metal around the keyway area. This was rubbed down with emery cloth until enough metal was taken off to remove the large spacer, thence the small primary sprocket and the rest of the clutch ect.
One of the three studs that hold the Stator to the inner primary case felt a bit wonky. It's casting, the top right one of the three, then broke away in my hand? This revealed a nice hole big enough to put a screwdriver blade through? With the inner primary case removed, this revealed the g/box sprocket for the first time in my ownership. The large hexagonal on that, with the lock-washer still intact, was barely finger tight. That was replaced with a 18t sprocket I've been meaning to fit. A used inner primary (£30) came from Price Part plus a used Stator/Rotor (£35). These are take-off units from his Diesel conversions and priced very competitively. All new gaskets and hexagonal nuts/washers ect were also sourced from Price Part.
It's all back together, problem being, I cant get enough air clearance on the Rotor/Stator. I've already enlarged all three holes on the stator and filed a lot of metal off the stator pick-up and even the rotor itself. I finally got full clearance, but, it's doesent look good, with quite large gaps for 75% of the circumference and 8thou between two of the other pick-ups. I'm now convinced looking down at the Rotor Nut, as I'm kicking over, that the end of the crank is now out of true. Must have been a helluva' lot of force on that crank when the rotor broke up. A shame that such a low mileage engine has gone bang so spectacularly. Could say I've had a good run, as the last time the primary was taken apart was some 6,000 km's ago, no problems until now.
I do wonder whether the recent tweaks to the jetting/exhaust, which has revealed a "hidden side" of this Bullet with it's now stonking mid-range and top end, whether said tweaks have put too much strain on other bits. I do like to ride it hard, but maybe I've cooked my Turkey this time?
The moral of this tale. I just dont know, as wonders cease to amaze me with the quirkiness of these Bullet's?
Will fire it up on Boxing Day, for the first time since I put it all back together, and do some testing. Fingers crossed it might be ok?
Off to get my Xmas dinner now on my trusted 50 year old Raleigh cycle, which never lets me down.....
Seasons Greetings to One & All.
BT
My Bullet has been very quiet recently! In fact, after getting the M.O.T/Tax done towards the end of September, my bike has hardly turned a wheel since. I thought I'd developed a charging problem and checked out most of the system with a test meter. The fairly old battery was replaced for less than £17 (from the re-vamped Hein Gerhicke chain, filled with acid with the bottle supplied). This went flat within a few weeks of local commuting use. More testing and I thought the regulator was shot, so that was replaced by a single unit, that actually replaces both the Indian Reg/Rec units. This was £25 from Henry at Price Part. Alas, still not enough volts getting to the battery. Headlight was getting feed from the Alternator, and one out of the two charging circuits was showing over 45v at speed, the second circuit was barely over 8-10v.
Time to take the primary cover off. Oh dear, what a mess (or words to that effect?). There are people here that just know what is coming next I'm sure? The large hexagonal nut on the Rotor dropped out with the oil, it's collar was sheared off and still on the crank. The large spring washer was attached to the bottom of the stator. The Rotor itself had shifted along the crank, causing said hexagonal to make plenty of contact with the outer primary cover, A lot of metal, shrapnel would be the best description, was in the oil ect.
Upon removal of the Stator, this revealed the full state of the Rotor, with no less than four of the six metal inserts missing/destroyed. A large chunk of one these inserts was actually embedded into one of the stator windings to a depth of some 1/4 inch or so!.
It took some persuasion with a three-legged puller to get the Rotor off. This revealed the woodruff key was sheared and there was quite a build up of excess metal around the keyway area. This was rubbed down with emery cloth until enough metal was taken off to remove the large spacer, thence the small primary sprocket and the rest of the clutch ect.
One of the three studs that hold the Stator to the inner primary case felt a bit wonky. It's casting, the top right one of the three, then broke away in my hand? This revealed a nice hole big enough to put a screwdriver blade through? With the inner primary case removed, this revealed the g/box sprocket for the first time in my ownership. The large hexagonal on that, with the lock-washer still intact, was barely finger tight. That was replaced with a 18t sprocket I've been meaning to fit. A used inner primary (£30) came from Price Part plus a used Stator/Rotor (£35). These are take-off units from his Diesel conversions and priced very competitively. All new gaskets and hexagonal nuts/washers ect were also sourced from Price Part.
It's all back together, problem being, I cant get enough air clearance on the Rotor/Stator. I've already enlarged all three holes on the stator and filed a lot of metal off the stator pick-up and even the rotor itself. I finally got full clearance, but, it's doesent look good, with quite large gaps for 75% of the circumference and 8thou between two of the other pick-ups. I'm now convinced looking down at the Rotor Nut, as I'm kicking over, that the end of the crank is now out of true. Must have been a helluva' lot of force on that crank when the rotor broke up. A shame that such a low mileage engine has gone bang so spectacularly. Could say I've had a good run, as the last time the primary was taken apart was some 6,000 km's ago, no problems until now.
I do wonder whether the recent tweaks to the jetting/exhaust, which has revealed a "hidden side" of this Bullet with it's now stonking mid-range and top end, whether said tweaks have put too much strain on other bits. I do like to ride it hard, but maybe I've cooked my Turkey this time?
The moral of this tale. I just dont know, as wonders cease to amaze me with the quirkiness of these Bullet's?
Will fire it up on Boxing Day, for the first time since I put it all back together, and do some testing. Fingers crossed it might be ok?
Off to get my Xmas dinner now on my trusted 50 year old Raleigh cycle, which never lets me down.....
Seasons Greetings to One & All.
BT