primary question

splatt said:

So HOBOT, you will be throwing the key away then will you ,as it serves no purpose, might pay to keep it in your back pocket.

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He's not saying it doesn't serve a purpose, it's just that the majority of the restraint is done by the taper and not the key.

pelican said:

swooshdave said:

pelican said:

right on. engine is too complicated for me, I'd be too scared to mess something up.

my sparx rotor is undersize! - seems this is normal too from other threads

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It fits on the shaft but the nut won't fit inside it? Better to have to fit it so it's tight than have it sloppy.

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no, not even. the rotor is .7495 and my shaft is .7505...at least the rotor nut is good at .749

tried stator today... everything is way out on that too. The round metal is too wide to fit in the outrigger plate. the recess's in the epoxy are too narrow to fit the studs.

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You sure you're putting the rotor on the right way? :mrgreen:

I was totally stumped on the whole alternator installation until I saw how it was suppose to go on, then it made sense.

If you want more help post pics.

Filed down the edges of the rotor to make a small chamfer, and widened the keyway a little. Finally fit.

here's some pics of the rough fit of the stator...
metal too wide


even if the metal did fit the epoxy is not cut straight, and it starts rubbing


I guess a lot are like this from the threads I searched. i.e. roadscholar had this same problem. If you get one that fits out of the box consider yourself lucky


Oh, and related to mk3 primary. I read in some other threads it takes a while to for the hydraulic tensioner to fill up. In the manuals though it says you can prime them. Looking at the tensioner if you pour some oil down the top it will run down to the ball check valve where it will suck in if you squeeze them a few times?

pelican said:

Oh, and related to mk3 primary. I read in some other threads it takes a while to for the hydraulic tensioner to fill up. In the manuals though it says you can prime them. Looking at the tensioner if you pour some oil down the top it will run down to the ball check valve where it will suck in if you squeeze them a few times?

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Yes, the tensioner does need priming if its completely dry, however even if the small tensioner reservoir is completely filled it won't take very long for that oil to drain through the tensioner mechanism.

Also the tensioner outer plate (which forms one side of the oil reservoir) does not make a particularly good seal with the alloy body casting as it is secured on only one side of the "reservoir" part, so that's another potential leakage point. A gasket (066570) is available, (which isn't shown on the exploded parts diagram) but gasket sealant works just as well.

Mr Pelican, my Mk3 clutch basket also had a wobble. Seems that's how thew are meant to be.

graeme

thanks for the confirmation.

ok, last one- now that I've shaved down this outrigger plate is there a reason this triangle part is on there, or can I file that off too?

pelican said:

right on. engine is too complicated for me, I'd be too scared to mess something up.

had to stop 4 tonight
my clutch basket definitely has some wobble- I searched some threads where it says it's normal though?
my sparx rotor is undersize! - seems this is normal too from other threads

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Some wobble is normal. Not sure about the Sparx. My Sparx set up fit as it should with the proper tolerance between stator and rotor so I guess I got lucky for once.

I'm bored with 750 models assembly issues so learning 850ES stuff to convince me not to try. I'm pretty sure that with a proper taper fit a key way is just for initial alignment, even on the torque scale a Commando applies through it, If not then I'd expect to find more blacksmith welding of key to crank slot. I have found welded in keys on Combats and lawn mowers, but their fit was not that good.
I may try a key-less experiment, as nothing much should happen if it should slip, any more that with clutch slippage, as long as nipped up right for initial ignition timing.
If it fails to hold damn hi power loaded I'll eat my key way, if it don't slip - will someone here eat their words mis-quoting hobot message?