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#387339 - 08/01/11 6:57 pm Lucas E3L dynamo rebuild  
Joined: Oct 2007
Posts: 57
greg kazen Offline
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greg kazen  Offline
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Posts: 57
long beach, ca
I am about to attempt a rebuild on my E3L with replacement parts purchased from Hawker Electrical in the U.K. And I am wondering if there are any special gear or bearing removal tools I will need for the job or any advice anyone may have in general. Thanks

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#387355 - 08/01/11 9:09 pm Re: Lucas E3L dynamo rebuild [Re: greg kazen]  
Joined: Mar 2005
Posts: 9,970
John Healy Offline
John Healy  Offline


Joined: Mar 2005
Posts: 9,970
Boston, Massachusetts
The gear removal depends upon what you are working on. Some gears require a flat split puller:

http://www.bizrate.com/split-bearing-puller-tool/?sc=1

Scroll down to the 14 piece bearing puller set. This is all you would ever need.

The bearings themselves do not require any special tools. When new the commutator end is a slip fit and the drive end is a nominal fit and does requires a little pressure.


#387365 - 08/01/11 9:23 pm Re: Lucas E3L dynamo rebuild [Re: greg kazen]  
Joined: Jul 2006
Posts: 871
trevinoz Online content
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trevinoz  Online Content
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Joined: Jul 2006
Posts: 871
newcastle australia
Greg,
You will probably find the drive end bearing loose in it's housing so a bit of Loctite would not go astray on assembly.
You don't say which E3L you are overhauling but the ones with drive gears, the gear normally can be prised off with two screwdrivers adjacent to the keys but the BSA type with the sprocket on a taper is a bit more difficult.
To remove the armature from the drive end, I support the housing and drive or press the armature out.

Trev.

#387484 - 08/02/11 4:25 pm Re: Lucas E3L dynamo rebuild [Re: greg kazen]  
Joined: Oct 2007
Posts: 57
greg kazen Offline
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greg kazen  Offline
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Joined: Oct 2007
Posts: 57
long beach, ca
Thanks guys. The Dynamo is a E3L - LI-O 20035A It is off my 61 Matchless G12CSR.

#387537 - 08/02/11 8:59 pm Re: Lucas E3L dynamo rebuild [Re: greg kazen]  
Joined: Sep 2005
Posts: 25
michael c. Offline
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michael c.  Offline
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Posts: 25
suburban philadelphia
Don't want to diminish your efforts or anything, but there's a gent here in PA who is positively astonishing at Dynamo fix. I took mine to him on the July 4 w/e; he checked it, replaced and fixed all that was necessary and had me on my way inside an hour. The cost ? $50. His email is dougwood@netzero.net My only connection is as a very happy customer.

#387548 - 08/02/11 9:31 pm Re: Lucas E3L dynamo rebuild [Re: michael c.]  
Joined: Mar 2007
Posts: 1,152
Swan Offline
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Swan  Offline

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Joined: Mar 2007
Posts: 1,152
Winona, MN
The two exterior screws for the field coil are always a bitch. Use penetrant, heat and an impact driver, but plan on buying two new screws. If you bought the Hawker kit they should be included.

The service manual will help too. http://www.bolsover.com/lucas/sectionL2partA.pdf


1966 Triton
1962 BSA DBD34 Gold Star
1966 Triumph Bonneville
#387785 - 08/04/11 4:52 am Re: Lucas E3L dynamo rebuild [Re: greg kazen]  
Joined: Oct 2007
Posts: 57
greg kazen Offline
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greg kazen  Offline
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Joined: Oct 2007
Posts: 57
long beach, ca
Thanks again guys. Got her apart (not so easy, lots of pullers, etc) and now the gear, bearings, oil seal etc are all back in place. Next question is does it matter which field coil wire goes to earth, etc. They are both black and the originals were both orange. thanks.


Moderated by  Alan_nc 


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