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D1 Lucas rotor removal
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mikef
Chatham Kent
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April 15, 2019 - 8:46 pm
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Hi All.
     I wonder if anyone can help me out here. As Technical Officer I'm supposed to know it all, sadly I don't.
A member has asked me how to remove the generator rotor on a Lucas system D1. I could find no information anywhere. Even the parts lists and diagrams that I have turned up nothing.
Eventually he managed to do it with a 5/16" bolt and a piece of 1/4" rod but not quite sure how he did it. If anyone has some information I would appreciate it, I could possibly make such a removal tool if I knew the dimensions.
Here's hoping.
               Mike.

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johnsullivan
east sussex
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April 15, 2019 - 8:51 pm
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covered here ** Please log in to view **

67 D10. and a D7    2007 Honda Hornet FA. 93 Yamaha TTR 250 Raid, Sinnis SC 125. 78 Honda 90  75 Montesa Cota 247 an electric scooter of Famous make.

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mikef
Chatham Kent
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April 15, 2019 - 9:09 pm
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Hi John.
     Yes thanks, that thread was useful. Just need some dimensions and I think that I could make up something. Does anyone know what the original tool looked like?

Mike.

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JulianS
North Dorset
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April 17, 2019 - 9:31 am
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213.jpgPicture from 1950 all model parts book showing the extractor part 90 297

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johnsullivan
east sussex
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April 17, 2019 - 10:51 am
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67 D10. and a D7    2007 Honda Hornet FA. 93 Yamaha TTR 250 Raid, Sinnis SC 125. 78 Honda 90  75 Montesa Cota 247 an electric scooter of Famous make.

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mikef
Chatham Kent
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April 18, 2019 - 6:35 pm
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Hi Julian.
        Many thanks for the picture. I just now need to get some dimensions. Hopefully the chap that has removed his generator with a bolt and rod will be able to help with these.
I can now see how it works and what is needed.

John. The link that you have provided shows removal of the Wipac generator. Could I be missing something?

Thank you both for the help.

Mike.

 

   

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johnsullivan
east sussex
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April 18, 2019 - 8:18 pm
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No not really I chucked it in to possibly help show others the variation.

67 D10. and a D7    2007 Honda Hornet FA. 93 Yamaha TTR 250 Raid, Sinnis SC 125. 78 Honda 90  75 Montesa Cota 247 an electric scooter of Famous make.

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Martin_uk
Surrey
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April 27, 2019 - 9:42 pm
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Hope this helps

1953 D1 Plunger Lucas

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mikef
Chatham Kent
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April 28, 2019 - 12:31 pm
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Thanks for the link, I now know roughly what the tool has to do. I think the bar piece protruding from the end of the 5/16" bolt is 1/4" diameter, just need to know how long it should be.
Unfortunately I have never seen this Lucas set up and don't know anyone locally with one to experiment.
However it seems that Bantam owners with the Lucas generator have got around the problem using a length of rod and a 5/16" bolt.
So maybe making a tool is not necessary.
Mike.

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Martin_uk
Surrey
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May 1, 2019 - 9:20 pm
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I have just checked and the thread in the end of crankshaft is 1/4 BSF.

The rod needs to be a clearance fit say 5mm so passes through threads and bears onto bottom of hole.

The hole depth is about 20mm so add 5-10mm say 28mm for bar.

The 5/16 BSF bolt then screws into the rotor and end bears against end of bar thus pulling the rotor from taper.

The rotor is positioned by a pin in the crank and will need to be removed.

Mine was quite tight so got a bit damaged in process, so worth heating crank to see if it assists removal.

1953 D1 Plunger Lucas

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