Lucas E3LM dynamo - removing gear

[Ducvelo]

I have a series C black shadow, which appears to have been fitted in the past with the Lucas dynamo (which is I thing a series D fitment). It's no longer working, and I want to remove it to get it reconditioned. However, having undone the bolt PD 34 in its end, the gear PD15 doesn't pull off. As I think it's on a parallel shaft (with a key) I assumed it should pull off easily, but no. Should I use a puller and use some force - I've done some gentle hammering on the shaft, but I'm afraid of shattering the gear. There are also 3 tiny bolts (with tabs to lock them) screwed into what looks like a bastardised from of PD 28 - not sure what these bolts are holding, do I need to remove these (and not drop them into the primary case!)?
Advice greatfully received.
Malcolm

 

[mercurycrest]

Hi malcolm,
Everything sounds good until you say "three bolts", that's not standard...... my suggestion is "try not to drop them in the primary case"

 

[Ken Tidswell]

The pegs have sheared off the drive at sometime in the past. This is obviously a repair. Stuff some paper/rag in the slit and remove, with care as John says. Ken

 

[Ducvelo]

Thanks, will try this. Attached is a photo of the bolts (4 in fact), which seem to be holding the sprocket onto something.
Malcolm

 

[Howard]

Hi Malcolm

You say you removed a bolt, are you sure it wasn't a nut, like the one on the Series C setup?

I'm guessing, but I think you've got a modified Series C setup, with the sprocket PD15/1 bolted to the hub PD16 through the oil flinger PD28, and no PD17AS for some reason. See MO14 in the C Technical section on the home page. If you've got this, the hub would be a taper fit on the dynamo. Taking the 4 bolts out should leave you with the hub on the dynamo shaft, which will fit through the hole in the back of the chaincase.

This could have been done because the previous owner thought it would be better, or just because he couldn't get spares. We take the spares availability and the stockists for granted nowadays, but it wasn't always thus.

H

 

[bmetcalf]

Regarding dropping bits into the primary case, one time I was lucky and I rotated the engine backwards and the key appeared on the chain like it was on a belt conveyor. Another time I wasn't lucky!

 

[Ducvelo]

Thanks all.
I got the bolts undone, and the dynamo out, which gives barely 0.5v on a drill spin test, so needs to go off to repair. I've heard Sean Hawker is good - anyone got any experience?
It turned out to be a modified Series D assy, with the bolts going into PD33 (it's a lucas dynamo with woodruff key). There was no PD 17AS though - does this normally have pegs that attach the sprocket to PD 33?
Thanks for the help on the detective work
Malcolm

 

[Jim Richardson]

I have used the guy in Stoke on Trent, he advertises as Dynamos Dynamos Dynamos, he was quick and did a good job 01782 856839

 

[A_HRD]

There are other mag/dyn specialists who are cheaper and quicker, but if you want a quality job, you can do no better than Sean Hawker www.hawkerelectrical.co.uk I speak as a very satisfied customer over many years.

Peter B
Bristol, UK.

 

[Howard]

I have used the guy in Stoke on Trent, he advertises as Dynamos Dynamos Dynamos, he was quick and did a good job 01782 856839

This guy gets good reports from others in the North Staffs section. I rebuilt my own with good parts from Sean Hawker. You pays your money etc etc.

H