GP Flywheel

[dapper]

Doing up a lads scoot Series 2. His old brass centred flywheel had the rivets come loose and scored the inside of his mag housing. Anyway, we're upgrading to electronic. Crank is in and mag housing back on etc. Went to fit brand new SR GP flywheel and its catching when turned. I've dremeled back the scoring, but when you turn the flywheel and look along it, it's appears to be running out of kilter. Makes me think that when the boss was rivetted on by SIL it's fractionally out of true. Anyone esle had this? I've tried another flywheel of my own and it runs true and doesn't catch anywhere.

[Adam_Winstone]

What is catching where? You can find that certain flywheels do not tighten down on th etaper correctly because the woodruff key stands too tall/too proud, the bottom of the flywheel hits tall bolt heads (normally only a problem it thick washers are used or a combo of flats and springs)... or the mag isn't fully home.

Figure out exactly what is making contact and/or what might be forcing it to tighten off line.

Best of luck.

Adam

[Adam_Winstone]

Ahhhh, another thing to watch out for... some Indian stators do not sit well/flat in some mag housings (especially repro ones) as the stator base is a lttle too wide to sit on the machined flat of the mag housing. This is just as likely that the mag was not machined flat to a big enough diameter and the step/lip at the edge stops the stator from seating flush. I discovered this issue whilst trying to figure what was wrong with a pal's replacement Indian electronic kit that he was trying to fit/get going on the Kite HIll campsite IOW. I only noticed as there was a crack forming across one of the adjustment slot lugs

This may not be the case but it is certainly one to check.

Adam

[GP240]

GP flywheel + Li crank ?

[dapper]

Adam,tried both flywheels without stator in place and the new one runs out of true. Will double check again tomorrow. But think you may also be right about the stator plate fitting correctly inside of the raised rim inside the mag housing, although that's a separate issue. Out with the Dremel again.

[dapper]

Also Adam I'm using round headed socket screws with wavy washers to hold the stator in so nothing too proud there. I'll try another woodruff key tomorrow. As stated I've tried both flywheels on without the stator fitted and the old one of mine runs true but the new one from SR runs out of true. Will double check very carefully tomorrow and report back. By the way how do you put arrows etc. onto photos to highlight problems?

[Adam_Winstone]

GP flywheel + Li crank ?

... I had assumed that "Crank is in and mag housing back on etc." was said to inform us that the crank had been changed to a GP type... but you know what they say about assumption being the mother.... etc.

Maybe Dapper can confirm that the crank has been changed for a GP type? Otherwise... there's the problem

Adam

[dapper]

Yes brand new GP crank from Corrado. Everything put back together correctly and mag hosing correctly seated and bolted down.

[philz]

I'm pretty sure I have read somewhere that some Indian flywheels are off centre. It may have been on MB website.

[dapper]

Right, I've spent an hour in the workshop and am now happy that the new SR flywheel is running truer than I thought. I've applied chalk to various suspect places where I thought it was rubbing without success, so will continue until I've solved the fecker. I have an overhead illuminated magnifier over the workbench but still cannot see where it's making contact. I've measured the depth of the groove on the outer edge of the flywheel and compared to my other flywheel, but no joy. I'm tempted to try to rig up a drill so I can spin the fecker which may make the high spot more obvious or will give me a heat trace to identify where I need to fettle. I even gently filed where the balancing holes were as there appeared to be slight burrs at the top of each hole.

HOWEVER, referring to Adam's point about stators needing fettling to sit flat against the mag housing, I was surprised at how much I had to Dremel off the outsside of the slotted lugs to attain this. Now, as many rally going scooterists carry a spare stator due to the likliehood of an LT coil or pick up failing, I wonder how many of you have tried your spare against the mag housing??? It would be a bugger to break down at the side of the road, and think "That's OK. I have a spare stator" only to find that it won't sit flat against the mag housing, and you either have to sit there filing it down (assuming you carry a file or Dremel, unlikely) or be recovered home or on to the rally.
So I would strongly advise all of you to ensure that your spare stator has been tested for good readings and fits correctly against the flat of the mag housing.

Good point, well raised Adam.