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Hi Norbert,
The Piston Rally starts on Sunday 17th September. I will take the ferry to Santander on 15th. I can give you full details if you want. It's a great event, I think I have been 11 times now!

Regards,
Joe.

Has anyone else made the significant investment and fitted the Sachse ignition? I would be interested to compare notes! Two years ago, I had a major electrical meltdown (literally!) and all the coils on the alternator stator were badly damaged. The ignition coil wasn't involved and did keep working,...

Good morning, and once again many thanks for your replies. I did get it reassembled yesterday and I found two possible issues. First I now had a bit of float in the clutch basket, not a lot, about 0.2mm I would guess. Second, I am much obliged to Norbert for his photo, quite a nice way to both visua...

Thanks for the replies! The bike is back up on the operating table and I'll dismantle the clutch again today. The clutch outer basket is in great condition with no significant grooves or marks in the splines. I will have another look at it though. I have also replaced all the friction and metal plat...

Hi there, When I first put my 500 back on the road, I gave the clutch assembly a good clean and replaced the oil seals. It was fine and continued to be fine for several years. Last year though, when I was preparing it for the Piston Rally, the clutch started grabbing. I had no time to do anything ab...

Thanks for the info John, and especially for mentioning that the neodymium is brittle, I didn't know that. The ones I have are very small, about 10mm diameter by 3mm thick. They have a countersunk hole through them which is why I was thinking of screwing it to the sump plug - but I don't want to cra...

As someone said, this engine isn't awfully heavy, but another approach I've used with heavier engines is to lay the bike down on its side - with suitable padding of course. Then after releasing the mountings etc, you can either lift the engine out sideways or lift the frame off the engine, leaving i...

Hi John, Apologies, only just noticed your reply and question. My borescope is a cheap & cheerful item I got from Lidl one time with the "Powerfix" name. I'm sure there are much better ones around and I like the ones which link to your phone by bluetooth. Having said that, the one I ha...

Well I finally located the gearbox stopper plate. In fact it's in the left hand crankcase half and the two mounting bolts come through from outside, in the primary case. With a bit of judicious bending, the borescope can reach it through the oil strainer hole. Both nuts and washers are in place and ...

Well I've had another look round and I'm feeling more confident that there's nothing loose or floating about in the engine. I've checked those two Allen head bolts in the cylinder head behind the pushrods and they are both OK - washers in place and complete. I spent some time poking the borescope in...

First of all, thanks for the ideas! I did drag a magnet through the oil I had drained but no joy. I didn't think to put it on the end of a piece of wire and drag it through the crankcase, so I'll do that. I do have a borescope so I'll have a go with that as well. John, you mentioned the "stoppe...

The clutch on my 1978 500W has been getting increasingly difficult recently, so this afternoon I stripped it down for a clutch overhaul. I rebuilt the engine about 12,000 miles ago, so although a clutch overhaul was probably a bit premature, I wasn't too concerned about having to do it again. Anyway...

Hi all, Just a follow-up on the re-wound stator saga. I finally ended up with 50 turns of 0.8mm wire on each coil. It was just too difficult to wind that many turns of 1.0mm wire by hand on the short bobbins. I think a professional with a coil winding machine could do it, but the wire is too thick a...

First of all, I'm sorry this update has been so slow coming! Well with the stator wound at 30 turns per coil, 6 coils is producing about 30 volts at 4000 rpm - that is rms voltage, measured open circuit. That fell to just a few volts at idle speed, so I felt it was not enough and decided to do anoth...

Hi there, I'm not yet in a position to offer any advice, having just fitted the Sachse unit yesterday and since the bike is missing some important parts (wheels) I haven't ridden it. However setting the timing was an interesting exercise! I must say though that I very much doubt if a few degrees ext...