The BSA A7-A10 Forum

Technical => Lucas, Electrical, Ignition => Topic started by: Greybeard on 21.06. 2013 16:58

Title: Not charging
Post by: Greybeard on 21.06. 2013 16:58
Hi chappies,
Will you give me your advice please?

On my 1955 GF I'm not seeing a charge at the ammeter. It shows a small discharge when the pilot light is on and a larger value when the main headlight is on but no movement toward zero when the engine is revved. From this I think that the bikes ammeter is connected and working.

I've disconnected the dynamo connections and clipped the black lead crocodile clip of my multimeter leads across both dynamo sockets with the red lead connected to earth: the dynamo shows a voltage of 6.5v at tickover and rises to 14v or so when the engine is revved. From this I believe the problem is not the dynamo.

During the bikes restoration I fitted a Wassel electronic voltage regulator inside an old regulator box soldering the wires on to the terminals I've also soldered the bike loom connections to the regulator box external connections.

So, is it the regulator?

I understand that Wassell regulators are not popular with you lot, so should I just order a better unit? Recommendations please.

Any other suggestions?

Many thanks chaps!
Title: Re: Not charging
Post by: Beezageezauk on 21.06. 2013 17:41
I know where you're coming from.  Been there...done that...waiting for the t-shirt.

I would suspect your regulator.  I had 3 Wassel units on my A10 before I got one that worked.  Since then I've had 2 good ones from the same supplier but he was good enough to try them on his own A10 prior to dispatch.  That way I know that I can fit and forget.

Beezageezauk.
Title: Re: Not charging
Post by: Ethelred on 21.06. 2013 19:25
I replaced mine with a solid state one, a DVR2, from dynamoregulators.com. £48 and no more problems. Apparently they can be fitted inside the original casings if that's important to you.
Title: Re: Not charging
Post by: morris on 21.06. 2013 23:25

Same goes for me, only I have a Boyer Bransden on mine. It's a fit and forget.

http://www.boyerbransden.com/PBdynamo.html
Title: Re: Not charging
Post by: wilko on 22.06. 2013 01:30
Make sure it matches the polarity on your bike. Neg or pos earth?
Title: Re: Not charging
Post by: KiwiGF on 22.06. 2013 03:11
Graybeard, it sounds like regualtor, but did it ever charge?
Ive got a dvr2, works fine, but i must confess i nearly ruined it, after i got the charging going, by connecting the battery the wrong way  a bit later during the resto, lucky for me the dvr2 has inbuilt protection against that school boy error, but not all electronic regs will have that protection i guess......i dont know about the wassel unit.

By the way, your symptoms might be consistent with the battery the wrong way round.......and if you have done that it may be necessary to flash the field winding.
Title: Re: Not charging
Post by: Greybeard on 22.06. 2013 10:14
KiwiGF,
Yes, up to now the ammeter has been showing a move to the right when revs are raised. I haven't reversed the battery connections:  I have a soldered-on short lead from the battery that terminates in a tounged plug and socket under the saddle for ease of disonnection and top-up charging while the bike is off the road in the winter.

My naked dynamo voltage test demonstrated positive earth polarity.

I've ordered a DVR2 as I'm pretty sure the regulator is to blame.
Title: Re: Not charging
Post by: KiwiGF on 22.06. 2013 12:32
Hi greybeard i think youve drawn the right concluion please let us know the outome, sounds like the duff parts thing again!
Title: Re: Not charging
Post by: PaulC on 22.06. 2013 18:57
I have the same problem. Ammeter shows discharging when the lights are switched on and the engine isnt running, but stays stubbornly on zero when the engine is running, no matter how high the revs. Should I have engine running AND lights on to see the ammeter showing charging? My battery is on a charger/conditioner so is always fully charged when I first start up.

I'm afraid I'm too new to this to understand discussion about regulators and putting multimeters across dynamo contacts. Will I get any clues by putting a multimeter across the battery terminals?

Thanks

Paul
Title: Re: Not charging
Post by: Greybeard on 22.06. 2013 19:14
Paul,

My understanding is that when the battery is fully charged there should not be, (actually cannot be) any charge going into the battery, hence no charge showing on the ammeter. Try allowing the battery to flatten a bit by leaving the lights on without the engine running for a while and see if after that you get a small positive value at the ammeter as the system tops up the battery.

You have to remember that on a magneto machine the battery is doing no work until you use the lights, stop-light or horn. In a coil ignition system the battery is being worked all the time as it's providing power for the ignition.
Title: Re: Not charging
Post by: Ethelred on 22.06. 2013 20:31
Should I have engine running AND lights on to see the ammeter showing charging?

Yes.

When you turn the lights on it starts to discharge the battery, so the ammeter goes negative, then the regulator susses out the battery needs charging and kicks in so the ammeter swings back to the middle and should go positive.
Title: Re: Not charging
Post by: Triton Thrasher on 22.06. 2013 22:57
Paul,

My understanding is that when the battery is fully charged there should not be, (actually cannot be) any charge going into the battery, hence no charge showing on the ammeter. Try allowing the battery to flatten a bit by leaving the lights on without the engine running for a while and see if after that you get a small positive value at the ammeter as the system tops up the battery.

You have to remember that on a magneto machine the battery is doing no work until you use the lights, stop-light or horn. In a coil ignition system the battery is being worked all the time as it's providing power for the ignition.


You're right. With engine idling, switch on the headlight. The ammeter should show a discharge.

Rev up. The ammeter reading should rise to zero. If that happens, there is nothing wrong with your charging system.

 If the  battery was low, it may show a charge above zero, for a while.

Title: Re: Not charging
Post by: KiwiGF on 23.06. 2013 00:53
When I was setting up my mechanical reg (before buying a dvr2) i noticed the battery discharges through the dynamo at low dynamo revs, so it's not the lights drawing power from the battery? The electronic regs do not "waste" power like this, or at least not as much, and if its one of the better designs.

The lucas type ammeters are pretty inaccurate i suspect, but better than nothing!
Title: Re: Not charging
Post by: trevinoz on 23.06. 2013 01:55
Kiwi,
           The mechanical regulator should not discharge through the dynamo at low revs.
As the revs drop and the output voltage from the dynamo drops, the voltage will reach a critical value and the shunt coil on the cut-out will not be able to hold against the spring.
Also, when the output voltage drops below battery voltage, there will be a momentary reverse flow of current into the dynamo which will create an opposite magnetic field via the series coil on the cut-out and negates the magnetism from the shunt coil.
Clear as mud?

Trev.
Title: Re: Not charging
Post by: Greybeard on 23.06. 2013 10:24
Doh, now you've done it Trevinoz! PaulC has just dissapeared over the horizon!
Title: Re: Not charging
Post by: cyclobutch on 24.06. 2013 13:09
When my dynamo stopped working all it needed was a 'reflash'; might that not be the case here?
Title: Re: Not charging
Post by: Greybeard on 24.06. 2013 13:31
When my dynamo stopped working all it needed was a 'reflash'; might that not be the case here?


I'm not sure he actually has a problem.
Title: Re: Not charging
Post by: A10 JWO on 24.06. 2013 15:32
I tend to agree with Graybeard, my 1954 A10 has only done 20 miles since the rebuild and has a new charged battery fitted. It has never shown a charge on the amp thing because I have never used the lights. Next time I use it I will run it with the dipped beam like Ninja type people  and see what happens. If it goes flat I will still get home and get straight on the forum.

Regards Colin A10 JWO
Title: Re: Not charging
Post by: Greybeard on 16.07. 2013 12:33
UPDATE:
I fitted a DVR2 and still have no charge  *sad2* I may have to apologize to Messrs Wassell & Co.

I think my dynamo must be crook. Using a 12v test bulb,( F & D together, bulb earthed) I sometimes get a nice bright light, other times nuffink. Is it possible that the dynamo is breaking down under load?

I took the end off the dynamo while it was on the bike and cleaned the commutator. The brushes still appear to have enough meat left for the springs to press them to the commutator.
I've cleaned and tested the F and D connection wires on the end cap.

Any advice greatfully received.
Title: Re: Not charging
Post by: Greybeard on 16.07. 2013 12:36
My dynamo resistances are as follows:
D terminal to earth is 27.5 ohms
F to earth is 3 ohms
Title: Re: Not charging
Post by: morris on 16.07. 2013 21:39
My dynamo resistances are as follows:
D terminal to earth is 27.5 ohms
F to earth is 3 ohms
Can not confirm your D terminal but F is ok. Service sheet says 2.8 ohms.
I suspect something breaking down under load /vibration.
Could be the field coil shorting internally or earthing. They are pretty fragile.
Title: Re: Not charging
Post by: trevinoz on 16.07. 2013 22:44
The "D" resistance is far too high.
Have you cleaned the commutator and given the brush surface a bit of a rub?
You may have a high resistance between the brush and commutator. Sometimes the brushes seem to get a bit of a film on the rubbing surface.

Trev.
Title: Re: Not charging
Post by: wilko on 17.07. 2013 01:29
I've come across intermittent charging in the past and it turned out to be loose field coils.The iron core was tight but the coils surrounding it were loose.
Title: Re: Not charging
Post by: chaterlea25 on 17.07. 2013 12:06
Hi
Digital meters are a PITA doing these tests  *sad2*
A rough test is to wire a 20w bulb in series with the "D" terminal ( make sure to keep battery polarity correct)
then turn the armature one segment at a time and observe the lamp brightness
an open winding will be self evident

HTH
John
Title: Re: Not charging
Post by: Greybeard on 18.07. 2013 09:25
UPDATE:
I'm fed up!  *sad2* I keep thinking aha, this will fix it and it's still the same afterwards. Yesterday I stripped the brushes and backplate, (with the dynamo on the bike). After removing the brushes I checked their rubbing surfaces for resistance and found quite a high value - aha thinks I TrevinOz was right, the brushes have glazed and gotten a high resistance. I gave them a rub on some fine abrasive paper wrapped over a socket to maintain a radius. When they were put back in place but not connected I tested the resistance; brush lead, through armature to other brush lead while carefully turning the engine. I got approx 3ohms and approx 10ohm readings, (I reasoned that the lower reading could be because the brushes were bridging two armature segments - Parallel circuits). After reassembling the dynamo I have 5ohms to earth at the 'D' terminal and 'F' is still showing 2.9ohms. I've flashed the dynamo a few times.
With the engine running the dynamo produces a few millivolts with the correct polarity. It's looking like I need a dynamo overhaul.
Title: Re: Not charging
Post by: Greybeard on 18.07. 2013 09:36
Just a thought: Would one of you UK based readers have a working dynamo I could borrow?
Of course I would pay Courier costs. The loan would be until the winter arrives and I take the bike off the road. I'm planning to get my dynamo overhauled during the winter at Dave Lindsleys in Leominster. He did a great job on my Magneto last year. He gets the dynamo case replated and everything!
Title: Re: Not charging
Post by: A10Boy on 18.07. 2013 13:06
Grey
Why don't you give the lads at yeoman's a call, I'm guessing they will have a few decent ones in their shed. Half an hour up the M5.

Title: Re: Not charging
Post by: Greybeard on 18.07. 2013 17:15
Thanks A10boy I was unaware of these people. I've emailed them.
Title: Re: Not charging
Post by: Greybeard on 19.07. 2013 17:54
UPDATE:
I removed the dynamo from my bike and took it and my new DVR2 to Dave Lindsley at Leominster; the bloke who rewound and restored my magneto. He put the dynamo on his jig, connected up my regulator and ran the dyno up to speed. At first, no output but when he pressed the brushes against the spinning commutator it started to work. He cleaned the commutator and fitted new brushes. He reckoned, (and I agree) that my old brushes were probably the original ones, ( don't forget that the bike has been unused for 38 years)
I thought I had cleaned the commutator and brushes suffiently but obviously not enough. Worth bearing this in mind if you are having charging problems.
I haven't refitted the dynamo to the bike yet but I have high hopes of a happy outcome!
This work cost me 20 quid. I was sure I was going to need an armature or field coil, or both. He's a good chap is Dave! 
Title: Re: Not charging
Post by: KiwiGF on 20.07. 2013 04:55
Thanks for letting us know the outcome, i had a similar issue with brushes, except my dynamo would run for a few hundred miles then stop charging, cleaning  the commutator would give me another few hundred miles and so on, cured with new brushes. Its the first thing to check I reckon. In my case the dynamo would not "kick start" itself with f and d joined, but passed all other checks, it would start and keep generating if one put a little current through the field to kick things off. Too much resistance in the brushes was enough to prevent the "kickstart" was my conclusion.

I wonder how many people have bought new armatures etc when the problem was the brushes were faulty!
Title: Re: Not charging
Post by: Greybeard on 21.07. 2013 16:36
UPDATE.
First thing this morning I refitted my dynamo and DVR2.

NO 'KIN CHARGE!  *sad2*

[many hours pass]

Long story short; my DVR2 will not work if it's case is earthed.

I fitted the DVR2, (as I had fitted the Wassell unit) inside an old Lucas reg box with its fixing stud bolted through the paxolin and metal base. I've had to physically isolate the unit inside the case to get it to work.

Whilst testing I refitted my cheapo Wassell unit and, wouldn't you know it, it works.

So, is my DVR2 faulty?

Anyway, I now have a bike that charges its battery!!!!  *smiley4*


Title: Re: Not charging
Post by: morris on 21.07. 2013 17:25

Anyway, I now have a bike that charges its battery!!!!  *smiley4*


And a spare DVR2 incase the Wassel packs up *smile*
Title: Re: Not charging
Post by: Greybeard on 21.07. 2013 19:46
No; I have a spare Wassell in case the DVR2 packs up. ;/
Title: Re: Not charging
Post by: trevinoz on 21.07. 2013 22:38
I would ask Mike about the DVR2.
Title: Re: Not charging
Post by: KiwiGF on 22.07. 2013 00:05
My positive earth dvr2 is earthed and works, so something is odd with your one i guess? Is the wire on the dvr2 that sets whether it is 6 or 12v set up correctly for your bike?
Title: Re: Not charging
Post by: A10Boy on 22.07. 2013 10:27
I agree, I would contact Mike at Dynamo Regulators Ltd, or pm Manormike here.

Good news is you got it working.  *smile*
Title: Re: Not charging
Post by: Greybeard on 22.07. 2013 23:19
I've sent a mail.
Title: Re: Not charging
Post by: Greybeard on 05.08. 2013 11:58
Quote from: trevinoz link=topic=7273.msg51578#msg515i78 date=1374442686
I would ask Mike about the DVR2.

Right then,

I contacted ManorMike, (Mike Hutchings) at Dynamo Regulators;  he agreed to have a look at my DVR2. I sent the unit off and refitted my el cheapo Wassell gizmo which since my dynamo was fettled by Dave Lindsley actually does work, (see more about this later).

Mike confirmed that something had gone wrong with the DVR2 and it was earthing the dynamo output. I would not have been surprised to be told that I had done something to damage the unit  *work*, although I am not really that dumb with electrickery, (I was a telephone maintenance engineer for many years).

Mike sent me a new DVR2 last week and this morning I've had the opportunity to go to the garage and fiddle, (with the bike!).

A while ago you may remember we discussed using an LED to illuminate the ammeter and display charge state, (http://www.a7a10.net/forum/index.php?topic=6284.0).
I fitted one of these things back then: http://goo.gl/s2BCN3. I got a 6v positive earth version and fitted it, (with blue-tack) to the clear plastic outside of my ammeter casing inside the headlamp cowl. As my bike has no way of turning the device on and off and it is only needed in poor light when you cannot see the ammeter I wired it between the speedo bulb feed and earth.

After changing over the regulator units today I started the engine and wow; what a difference! With the Wassell unit in circuit with headlight on, engine revs raised, the ammeter was showing a move to the centre position so the regulator was attempting to balance the dynamo output vs battery load. The best I got from the LED device was a neutral amber light.

Now I have the DVR2 fitted, as the revs are increased the ammeter moves over from discharge to showing a healthy charging current; the LED device meanwhile changes colour from red to amber and then shows a good clear green! Obviously when the battery has been fully charged I'm expecting to see a neutral display from both devices.

I can recommend the LED charge indicator; it works  *bright idea*. However, I highly recommend the DVR2 and the super service provided by DynamoRegulators. Thank you very much Mike!  *respect*


Title: Re: Not charging
Post by: Dynamo Regulators Mike on 06.08. 2013 10:24
Glad you are pleased with the performance of the replacement unit Neil.
Yours showed a problem not seen before in several thousand units sold. I will do my best to ensure it does not happen again.
An extra up to 4 Amps available over the Wassel cheap but miserable 'regulator' is an emphatic improvement indeed (as shown in KenF graph under regulator thread. Sadly people will still buy on price alone.
Title: Re: Not charging
Post by: PaulC on 23.08. 2013 19:38
Great that Greybeard is charging again!
I have followed this thread with great interest, but sadly little understanding! Does anyone have a picture of a regulator in situ so I can identify mine? Also is there perhaps a picture of the F and D connections wired together and earthed to the frame? I think this needs to be done to "flash" the unit, but I'm not sure how that helps or what it does.

When I switch on my parking light the ammeter shows a draw of about 2 amps. Headlamp draws 6 but on a 45 minute ride with headlamp on, the needle stubbornly stays drawing 6 amps.

Any help would be appreciated.

Many thanks
Paul
Title: Re: Not charging
Post by: morris on 24.08. 2013 11:21
Hi Paul,
you will find your regulator inside the toolbox top left.
If it has a black case held on with a spring wire, it's probably still a mechanical unit, unless someone installed an electronic one underneath. Take off the cover, and if you see a couple of coils, it's a mechanical type.

You don't mention whether the current it's drawing with lights on is at tickover or running at speed.
You will not have a charge under approximately 1500 rpm, so its perfectly normal to see a discharge when for example standing at the red light and the lights are on.

F and D are connected together only to measure the dynamo's output.

Flashing" a dynamo is done to change it's polarity i.e. when changing from positive to negative earth or when in doubt of the dynamo's correct polarity.
This is done by connecting a wire to the + or - battery pole depending on whether you want it to be negative or positive earth, and with the other end touching (flashing) the F pole on your dynamo.
Title: Re: Not charging
Post by: duTch on 25.08. 2013 11:42

 Good you got it sorted GrayB, sometmes problems ulimately have the simplest solutions, but I think you've done enough of this ;-
Quote
had the opportunity to go to the garage and fiddle, (with the bike!).
What you need to do is take it out and have a good hard play....don't overdo it, and be close to home base (~couple of hours),before dark, just in case
Title: Re: Not charging
Post by: Greybeard on 25.08. 2013 14:41

 Good you got it sorted GrayB, sometmes problems ulimately have the simplest solutions, but I think you've done enough of this ;-
Quote
had the opportunity to go to the garage and fiddle, (with the bike!).
What you need to do is take it out and have a good hard play....don't overdo it, and be close to home base (~couple of hours),before dark, just in case
Indeed!
Title: Re: Not charging
Post by: PaulC on 26.08. 2013 08:48
Thanks Morris. I'll have a look inside the toolbox. The current draw with headlight on was a constant -6amps even at 60 mph.

Paul
Title: Re: Not charging
Post by: PaulC on 27.08. 2013 18:03
Not sure if this should form a new post, perhaps called charging for beginners?

I've looked inside my toolbox for the regulator and found this. Not what I was expecting. On the side it says www.nanocontrols.co.uk and it has terminals labeled F D A and E also a bright green wire in a loop with the instruction "cut loop for 12V". Checked on line and it looks like a V-Reg II. Is this suitable for a Super Rocket?
I have the blue wire attached to the F terminal which is correct for +Earth.

I've taken the cover off the dynamo and started the bike so I know it's spinning. Before bridging the F and D terminals to test for output, do I have to disconnect the green and yellow wires and if so, how? They seem to disappear into the body of the dynamo. See attached photo.

If there's no output on the volt meter (that I haven't yet bought!) then bushes are next. How do I remove them? Do I just use tiny pillars to move the retaining spring out of the way, or does it come off completely? BTW, the wires connected to the bushes and terminals seem very thin. Is this normal? Can you tell from the phot if my bushes are particularly worn? Also, there are a blue and a black wire that seem to link the bush wires to the armature casing. What are these for?

Thanks for any help you can give.

Paul



Title: Re: Not charging
Post by: a101960 on 27.08. 2013 19:23
To test the dynamo output you will find it easier to disconnect the dynamo output wires at the regulator connections. The dynamo output wires shoud be coloured yellow for "D" and green for "F" The attached image shows how to test the dynamo. Join the two dynamo output wires together and connect them to a multimeter set to DC volts, or as in the picture use a spare lamp. Hope this helps
John
(http://)
Title: Re: Not charging
Post by: Ethelred on 27.08. 2013 19:44
If you follow your link to nanocontrols you'll see detailed fitting and testing instructions for the regulator.
http://www.nanocontrols.co.uk/auto/v-reg2.htm (http://www.nanocontrols.co.uk/auto/v-reg2.htm)
Title: Re: Not charging
Post by: duTch on 27.08. 2013 23:14

 Hi Paul, normally the blue wire should be purple, and connect between 'A' and the other end to Ammeter, but I believe some of those aftermarket jobbies make up their own codes...??
 Irrespective of the colouring, just make sure both ends of any wires connect to the relevant contacts...often a trap.!

 Also, the bRushes (they called bRushes 'cos originally they were made from wire strands, like slot car contact bRushes) are serviceable until the wires 'hang up' on the holders, but pull 'em out and give them a clean- as you say, move the spring aside.

 Cheers ,duTch
Title: Re: Not charging
Post by: trevinoz on 28.08. 2013 04:46
Paul,
           The wires are held in position by the retainer plate which has a screw in the centre.
Loosen the screw and pull the plate back as you go. It will come away but the screw will stay in the plate as it is threaded in. Pull the wires out.
BUT, it will be easier to do the test at the regulator, just disconnect the "D" & "F" wires and join.
Any decent multi-meter will suffice, use the 20V scale. (DC).
The brush length looks OK.

Trev.
Title: Re: Not charging
Post by: PaulC on 28.08. 2013 08:31
Thank you all for your replies. Very helpful. I'll let you know how I get on.

Paul
Title: Re: Not charging
Post by: A10Boy on 28.08. 2013 09:08
You might find it easier to pull the F and D wires from the regulator and do the test at that end, [connect together and bulb or voltmeter] it saves having to do a bridge link at the dynamo end. You will only need to test the dynamo end if it doesnt show good volts to eliminate a broken wire between Dynamo and Reg.

A friend of mine against my better judgement and advice, bought a Wassup regulator for his AJ which I fitted. Unbelievably the wiring colours dont match with the Lucas F A D E colour code which was used on 90% of brit bikes of the era! Luckily I didnt trust it and the diagramme was useless, typical of them, but we got there without blowing it up.
Title: Re: Not charging
Post by: PaulC on 28.08. 2013 18:23
Well, I took the F and D wires from the regulator and used a circuit tester to make sure the wire at the regulator responded to the wire at the dynamo. And they both did, so no breakages. I then connected the F&D together, started the bike and checked for charge with the (new) voltmeter - no reading at all, even with the revs high enough for the bike to start walking backwards on its centre stand.

So to the brushes. Because of the orientation of the dynamo I could only get one out without removing the whole unit and that's beyond me at the moment. I presume it just pulls out when the band round it is loosened. Anyway, I cleaned the one I could get at and tried again - still no reading.

I put it all back together and went for a long ride instead, followed by a beer!

I think trip to Leominster is on the cards. Can it be tested in situ or will I have to remove it and take it separately? If so it'll have to wait until the end of September.

Thanks for your help.

Paul
Title: Re: Not charging
Post by: Greybeard on 28.08. 2013 19:47
Dave Lindsley will want to put the dynamo on his test rig. I took my dynamo, (and chain) off and made a quick blanking arrangement so I could ride there.
Title: Re: Not charging
Post by: PaulC on 31.08. 2013 08:47
Thanks Graybeard. Is it easy to remove and refit?
Title: Re: Not charging
Post by: Greybeard on 01.09. 2013 13:55
Disconnect the dynamo wires.
After removing the timing cover and cleaning out the old grease undo the dynamo strap and rotate the dynamo to loosen its chain.
There is no need to remove the sprocket on the dynamo.

If you are going to run the engine without the dynamo, remove the dynamo chain. To remove the chain you have to remove the large dynamo drive sprocket. I used a mixture of leverage and light taps to free the sprocket from its taper. You can now remove the sprocket and chain.

I was not able to wiggle my dynamo through the engine plates, (I don't know if it's supposed to be possible) so I removed the drive side engine plate. Be carefull to look after the large cork washer that seals the dynamo to the timing cover unless you are going to replace it.

I made a blanking assembly by cutting a disk of ally sheet to cover the timing chest dynamo mating surface and held it in place by screwing it to a piece of wood inside the case.

When reassembling rotate the dynamo body to set the chain tension; while tightening the dynamo strap make sure to press the dynamo into the timing case to seal it against the cork washer. Check the dynamo chain so it has no more than about 1/4" slack. You'll need to rotate the engine and check the chain in various positions to ensure the chain is not too tight or too loose.

Put a large glob of soft grease in the dynamo chain-case. It might be useful to lay the bike over while doing this so grease doesn't run onto the timing cover mating surfaces. I use Hylomar Blue for sealing gaskets.

Engine plate on, reconnect dynamo, jobs a goodun!

I'm expecting someone with a lot more experience than me to tell me of my errors in the above! ;)
Title: Re: Not charging
Post by: a101960 on 01.09. 2013 16:10
I would just add that the dynamo should pass through the engine plates. It definatley does on mine. And I would advocate using grease on both sides of the timing cover gasket to seal it. That is what I use and it has always worked for me. If you use grease the gasket can normally be used several times without needing replacement. And don't forget like I did to get an old piece of cardboard, and punch some holes in it so that you know which screws go back where!

John
Title: Re: Not charging
Post by: PaulC on 01.09. 2013 19:04
Thanks for the comprehensive instructions. I think I'll leave this for a winter project when I won't be wanting to ride my Rocket, so I won't need to make the blanking plate.

Paul
Title: Re: Not charging
Post by: Greybeard on 01.09. 2013 21:22
If the blanking is worrying you I expect duct tape would be ok if the metal was cleaned properly.
Title: Re: Not charging
Post by: PaulC on 23.10. 2013 19:06
It is now!!

Thanks to your helpful responses, I summoned up the courage to have a go at removing my dynamo and regulator so I could take them both to Dave Lindsley. This is by far and away the most adventurous mechanical work I've undertaken and I wouldn't have tried it without your instructions. A big big thank you to you all.

When Dave put it on his test bench it turned out that the dynamo was actually OK (other than soft brushes), but the regulator was suspect. Dave fitted new brushes and I bought a shiny new electronic regulator. I refitted everything yesterday and this morning and can now ride with dipped beam all the time, with the ammeter showing the battery taking charge. Chuffed to bits.

Thanks again.

Paul
Title: Re: Not charging
Post by: Greybeard on 23.10. 2013 20:02
Great news Paul. I'm happy that this forum was able to help you.
Title: Re: Not charging
Post by: morris on 23.10. 2013 22:18
Very nice Paul. As the old saying goes, learn from what you make and learn from what you break. (may have just invented that one though....)
A couple of days ago I tried to remove the timing side cover to have a look at the belt drive I installed some time ago. Couldn't get it of, it was like the gasket sticking on one side. After 15 minutes of careful wiggling,  it still refused to come off. I stopped, went out for a smoke, came back in and noticed I had left one bolt in.... *red*
BTW belt drive still looks as new after about 500 miles.