Sparx Alternator Report

Hi all---

I recently installed a Sparx high output alternator on my 1975 Mk III. Here's what I learned.

Good part: The alternator works just like they say it does. High output at low RPM, which is just what I wanted. My bike has a 22-tooth front sprocket and around here I don't ride very fast, so most of the time I am cruising at a hypnotic 2500 rpm. The alternator keep the battery fully charged with the headlight on. And now the stock Norton electric starter works well all the time. No alterations needed. I am using an Odyssey gel cell battery which is considerably better and larger than a stock lead-acid battery, but it still fits into the battery box.

Bad Part: The Sparx alternator is made in China and I swear everything from that lousy country is pure crap. They cannot make anything with any degree of manufacturing quality. (end rant) I needed to ream out the center mounting hole for the rotor to 0.750" as it was a few thousandths undersized, and I had to file every one of the stator holes and the plastic of the stator itself so it too would fit. Out of the box, it was completely unusable. If you have access to machine tools and are clever it can be made to work, but beware if you expect it to just bolt on.

--Scott
'75 Norton Mk III

I did the same thing .Had to put all 3 in my lathe for the supplier and ream them.They were .001" under not over.Pretty pathetic.I swear anything aftermarket I put on my 68 it regects. I treated it to a boyer ,single lead coil and new battery 5 years ago as a treat for running so good on stock ignition. It straightened me out quickly and I put the stock flint and steel back in and sh_____ canned the coil and boyer.I lubed the autoadvance with my high temp BMW grease( not made in china )and it has run pefect ever since.I bought a the same spark,but have not put in my 71 yet.A little scared to try it.This morning I went to change my air filter on the 68 and the new rubbers I had in stock for the last 3 years cracked and now I have to order new ones. I guess stock chinese parts disinigrate from sitting . Sorry for all my ranting.
Bruce

I like it how you guys assume it'd the Chinese parts that are out of spec and not the English ones...

I have a Smithy 3 in 1 machine. I have done so much with this. Milling cases, turning down hubs for oring chain, numourous releavings (inside and out) the list is endless. I feel Norton owners either need machines like this or good friends with them.

Scott, I am glad you got it sorted. As long as it was not DOA (sort of) you should be good.

Yeah, something serious happened with the QC where ever the Sparx rotor and stators are manufactured. About two weeks ago I fought with a rotor bore that was undersized, and the three recesses for the mounting bolts had to be made larger for clearance.

This differs from my previous experience though, where the units were direct bolt on with zero fitment issues.

How long have they been made in china?

Wassell rotors/stators are also made in China.

On a side note, my Sparx rotor/stator fit on perfectly.
Do you think people in China bitch about poor quality items made in China? I bet they do, then the government covers it up.

pelican said:

How long have they been made in china?

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For as long as they have been selling them.

The first batch of Sparx had undersize bores on the rotor, they corrected this for later batches, must be a lot of old stock around or they have reverted to undersize again.

scott12180 said:

The Sparx alternator is made in China and I swear everything from that lousy country is pure crap. They cannot make anything with any degree of manufacturing quality. (end rant) I needed to ream out the center mounting hole for the rotor to 0.750"

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I don't believe we should be blaming the Chinese, as apparently the Sparx rotors are purposely bored undersize.

post30566.html#p30566

maylar said:

I contacted Sparx about that and the reply was:

"the rotor should be a 4 thou interference fit
you can ream it to 3/4" if you want the normal lucas style sloppy fit
Thanks
Andy"

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I checked 4 cranks I have atlas and commando and they are all spot on .750".
With there reasoning they should send adjustable reamers with every sparx after all if they were made in china that would only add a couple of dollars on the cost.
Bruce

bchessell said:

I checked 4 cranks I have atlas and commando and they are all spot on .750".
With there reasoning they should send adjustable reamers with every sparx after all if they were made in china that would only add a couple of dollars on the cost.
Bruce

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I think they meant to take a big hammer and pound the rotor on. That should produce zero slop. :roll:

I do wonder, as the Chinese industry has expanded so fast. Where have all the trained people come from?
Proves a point, they are probably Rice farmers on a CNC machine.
We had some Titanium parts made in China, the 1st 6 off samples were lovely. The next 100 off were of inferior material.

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One day, everthing will come wrapped in plastic. Oh! it already is.
So much for pollution.

Sure the Chinese makers are liable to produce sub-standard crap. But who is contracting them and responsible for the QC? Sparx is a British company that alleges it has the original Lucas drawings. I have witnessed correspondence between the manager of Sparx and a very competant British bike restorer, highly qualified in mech eng QA, that clearly showed that Sparx had no interest whatsoever in the science of metrology as far as dimesions and tolerances are concerned with his rotor products. Further his appalling ignorance of general good mechanics practise and understanding of component stress as his advice was to "bash it on with a hammer"when nearly 0.002" undersize was found! And this company also manufactures ignition switches that simply do not assemble correctly. They are completely defective. This person who manages Sparx, his name is Andy. We call him Handy Andy. You can guess the metaphor.

Mick

If you've ever seen a modern manufacturing facility in China you'd know that they don't produce "crap" unless their customers ask for it. They have the technology and the desire to be world class, but you get what you pay for. If Sparx' specifications are for an "interference fit" on the rotor hole then that's what we'll get.

I still have a Sparx rotor that needs reaming. I'm not a machinist.

maylar said:

If you've ever seen a modern manufacturing facility in China you'd know that they don't produce "crap" unless their customers ask for it. They have the technology and the desire to be world class, but you get what you pay for. If Sparx' specifications are for an "interference fit" on the rotor hole then that's what we'll get.

I still have a Sparx rotor that needs reaming. I'm not a machinist.

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Send it to me with 4.95 for return shipping and I will ream it for you. Some of the better parts suppliers run a ream through all of them before they get sent out. It may take all of 60 seconds. Jim