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Bullet's D7
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Bullet
Isle of Wight
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March 16, 2019 - 11:24 am
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Whilst not a full restoration, I thought my post in the new member section probably wasn't the right place for my D7 fixing rambling! So here is my D7 that has been wired by Stevie Wonder, and spanner'd on by Fred Flintstone! I'm not planning on painting and polishing it yet sticking with the oily rag method. 

Looks ok at first glance but has been wired with mains 3 core cable and the stator's been fiddled with, everything is running on AC so the battery is fried and the horn doesn't work,   The clutch went the first time i rode it, the front brakes are hilariously bad and there seems to be 1/3 metric, imperial and whitworth just to keep all bases covered!  I'm sure ill find other issues as I delve deeper.Bantam-Ad-pic-1.jpg

 

So I already tackled the wiring and posted in the technical section on that one as wiring isnt my strong suit! It needs a new loom and a new headlight switch to replace the toggle switch thats been fitted, so I'm going to attempt the trailer cable loom rewire and if i fail miserably a pre made ebay loom. The bit I'm really not sure about is the Stator wiring as mine isn't right, so need to hunt down a picture of how the stock single switch stator wiring should look!

 

However todays job was fixing the clutch, already got uprated Rex Caunt plates and heavy duty springs to go in, Can you see the previous owners mistake?

IMG_3134-1.JPG

Yep, the clutch springs were held in with the outer plate, not the inner circlip retained plate.... There was just enough pressure on the springs for the clutch to kind of work but I'm surprised it made it as far as it did before the slipping simply stripped the clutch plates, it's a shame as they don't look that old. Now its apart I have discovered there is a little play in the clutch basket so new bushing required along with another special tool, mayaswell do the thrust washer while its off so back to ebay for parts!

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bart
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March 16, 2019 - 11:40 am
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That looks like a nice bantam, my sort of bike,  best one`s the D7 !

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March 16, 2019 - 12:42 pm
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My favourite D7 model, that`s why I bought one too, and also most parts to convert back to original from its current "trials" look.

That was some bodge by a previous spanner on the clutch. Looks like the gearbox has been running on mud/silt, can see a big dollop resting near the feed hole for the o/s inner crank mains.

Watch that sidestand during this wild&woolly weather, they are prone to not doing what they`re intended to.

I don`t think I have a harness to copy for the single-switch set-up, so will also be creating my own. Plenty of wiring diagrams kicking about here and other online sites, plus page 80 & 81 of the old Haynes manual. That manual uses a D7 for its strip down, so pics abound....not much cop for other models in that respect though. 

Any chance of pic of the ignition-charging side?

Blue

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sunny
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March 16, 2019 - 1:13 pm
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how  can  i  xplane   how   much   is  difrant    on  a  D 7    MODLES     ,, the  single  switch  D  SEVEN    WIERING  DYAGRAM     ISNOT   in  the  Haynes   MANUAL      CHAPs        AND   the   fywheel   of  the  Austin  MEASTRO     iiS  NOt  bolted  to  the  Crankshaft  ,, so   rethink how  you   do  the   jobs  on the  D 7  please

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Bullet
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March 16, 2019 - 1:19 pm
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The gear oil that came out did look pretty grim! Most of the 'lumps' are actually bits of clutch lining though, it will get a good clean out when i pull off the basket to fit a new bush and thrust washer.   The loom I was going to follow one of the diagrams on here, but my stator plate wiring doesnt look stock anymore so need to fix that so it matches the loom layout I use! I'm going to keep an eye out for another second hand stator plate as one of the posts on mine has been bodged with solder at the moment. I haven't delved deeper into that one yet though as the lights 'kind of' work at the moment, so fixing the clutch first so I can ride it 🙂 

IMG_3128-3.JPG

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March 16, 2019 - 1:59 pm
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That`s a very busy stator plate, looking at how the wiring has been directed in places, looks like someone`s rewound the coils and decided to do their own interpretation of things. Because it`s been modified, there`s nothing out there re a standard set-up to compare with yours. I would suggest getting a multi-meter on the job and see what`s being pushed out from those lighting/charging coils.

** Please log in to view ** ....as in second diagram, yes??

Blue

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Bullet
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March 16, 2019 - 3:41 pm
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The Direct AC headlight / DC trickle charge diagram? That was my plan. There's so much linked together on that stator, I don't really know where to start with the multimeter! Going to take of the plate and see how its wired on the back, I'm strongly tempted to just undo everything and start from scratch.

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sunny
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March 16, 2019 - 5:25 pm
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 LEON      JUST    PUT  UP  Photos   dont  tack  it  apart   .  I Wiil  be    able  to  IDENTIFY  if  i    can   see  the   wiers    from  the   coils CLEARLY   ,,  AND  do  you   have    the   P M simble   at  the  top  of  the  page   

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bart
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March 16, 2019 - 7:07 pm
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sunny said
how  can  i  xplane   how   much   is  difrant    on  a  D 7    MODLES     ,, the  single  switch  D  SEVEN    WIERING  DYAGRAM     ISNOT   in  the  Haynes   MANUAL      CHAPs        AND   the   fywheel   of  the  Austin  MEASTRO     iiS  NOt  bolted  to  the  Crankshaft  ,, so   rethink how  you   do  the   jobs  on the  D 7  please  

Where does the Austin MEASTRO (Maestro) come into all this ?  dunno

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March 16, 2019 - 7:35 pm
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sunny said
how  can  i  xplane   how   much   is  difrant    on  a  D 7    MODLES     ,, the  single  switch  D  SEVEN    WIERING  DYAGRAM     ISNOT   in  the  Haynes   MANUAL      CHAPs        AND   the   fywheel   of  the  Austin  MEASTRO     iiS  NOt  bolted  to  the  Crankshaft  ,, so   rethink how  you   do  the   jobs  on the  D 7  please  

You`ve lost me a bit there too Sunny, (done loads of work on Maestros, including saloon/van to truck engine conversions 🙂 ),  but I`m sure you`ve got a good explanation, I do follow your knowledge on ignition and wiring... 

As I suggested to Leon, page 80 and 81 of old Haynes manual shows D7 wiring diagrams.They are both single switch, I did check before posting because I`m not top of the class for electrics 😉    p80 nice simple single switch Direct lighting diagram,states also D7( but not seen that one on a standard D7)....and p81, Battery lighting,single headlamp switch, as my 1960 D7 has. Are you saying Haynes got these wrong? Wouldn`t be the first time I suppose.

Blue

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sunny
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March 17, 2019 - 10:45 am
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hi    Blue   like  the  MEASTRO  s  flywheel the    D 7 s  eletrix   isnot  quit   wot  it  seems ,,.. the  handbooks  conferm   this      ,  page  80 s  dyagram  is  with a  small H/LAMP   switch    it is   usly    for  the   D 7   Export   PASTORAL    A/C  dyrect   lighting    modle  also  used  on  D 1 ,3& 5   with  biger h/ lamp switches   till   1959 ,.,.    your   D 7  may  have  a have  a  FULL  D/C batery   system    [  page 81  ]   becouse  it was  fited to  the  D ONE s  till  1967  ,.,.   the    D 7  sngle  s/w   batery    system    was  fited    as  stanard     ,the  headlamp   dont   work  unless  the  motor  is  runing     as  with  ALL D 7 s   electrx   apart  from   yours  ,,   so  the D 7 s  single   switch    dyagram    ISNOT  IN THE   HAYNES  MANUAL      , and  so  the  second   photo   that comes  up  on  that  popup   thing   is  very   missleading   as is [  page 81 ]    in  the  manual     ,.,.  I  do think   LEON  s   gen  is  wot  it  says  it  is  a   1552  spec   as its  very  comon to  fuse  the   lamps  wen  its  been  buggerd we  will  see  if  i can  see  the   way  its  wierd up  a   ,    i   hope  that  explans   my  coment  

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March 17, 2019 - 12:41 pm
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Very well explained Sunny.

Hope you can get Leon sorted.

Cheers

Blue

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bantammad
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March 17, 2019 - 9:23 pm
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Hi bantammad ere just apoint the black and white wire is it to a kill switch or button?? Regards Les

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Bullet
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March 18, 2019 - 8:20 am
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bantammad said
Hi bantammad ere just apoint the black and white wire is it to a kill switch or button?? Regards Les  

It goes through a rather shoddy 'key' kill switch thats been fitted to the battery compartment cover, other end goes to ground on the crank case just outside the stator cover. I might replace the switch with a better one as its a bit rubbish, but having a key is handy!

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Bullet
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March 28, 2019 - 9:00 am
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New Clutch in and I think I should have listened to Rex when he said I probably didnt need the uprated trials springs...... Still it doesnt slip anymore!

New bush and thrust washer aswell as i had play in the cluitch basket, bush was a tight fit and seems to have caused a little clutch drag even with the lever pulled. hopefully that will bed in!

I got a cheap second hand clutch compressor tool (which is a bit rubbish) but thought Id make a holder tool out of an old plate!

rubbish.jpg

This did not work and folded in half like a pretzel! Undetered and with 2 old plates left i had another stab at it!

good.jpg

This one worked great! 

Clutch all done I ventured out on a its first rideout with the club (Wightriders MCC) and my engine tried to escape the frame! The two front engine bolts had loosened themselves and the onboard toolkit left by the previous owner was useless! Luckily other riders on the rideout were better prepared than me and had tools embarassed after tightening those it ran faultlessly all day doing about 80 miles (mainly at wide open throttle to try to keep up!) managed 60 down hills and 30 up the steep ones which i dont think is too bad.   it does still like to pop bulbs though so re wire is the next job!

 

Bantam-Copy.jpg

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