I burned up two 3 phase in short order on the 74' Commando I just rebuilt this past winter. I attributed it to having adjusted the primary chain too tight, causing excessive crank flex, and sloppy tolerances from the stator and rotor manufacturing. I also run the Tri-Spark MOSFET. In my frustration, I bought a Sparx 3 phase and had .010 shaved off the rotor, which is also a Wassel/Lucas replacement. Then, using a strip from a soda bottle as a spacer/gauge, I turned the engine over about 1/8th of a rotation each time and marked where I was still getting a tight clearance. Next, I used a Dremel to take away material from each place I experienced a clearance issue. Sounds extreme, I know, but after $400.00 burning up, I was will in to try anything. The Sparx stator is much cheaper than the Lucas.
Looser primary chain and more clearance and I am getting 14.6 Volts at the battery when revving the engine. So far, so good. I have installed several 3 phase stators and Tri-Spark MOSFET on unit Triumph using the soda bottle spacer and have had no problems. I think the over-tight primary chain pulling on both the gear box and the crank shaft have played more of a role than heat generated electrically. I admit, I am just a hacker and make no claim to know anything. I just have suspicions ....
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