I wish I had remembered that this thread was one here, having spent the past few days trying to fix the Dynastart on an ex-Police bike I picked up before lockdown, and which turned out to be in considerably worse condition than described. In a sulk, I pushed it away and pretended it wasn't there, until last year, when a minor issue with my other one forced me to pull it out. To cut a long story short, the Dynastart didn't work, and some minor investigation revealed that the belt was slipping, and too slack, even on maximum adjustment. Some more investigation revealed that the belt was too small to fit over the flywheel, but despite attacking the locking ring with my impact gun, it refused to loosen off, so I reverted to kickstart, and forgot about it again. This month, I was doing some more work, to replace the coil and condenser to try and resolve a persistent misfire at low rpm, and decided to have another go at the flywheel. This time I locked the flywheel using a standard G-clamp, bearing on the kickstart, with a sheet of lead flashing between for protection. The locking ring was already chewed up badly where someone had attacked it with a chisel, so I selected a blunt punch and with the flywheel locked, it came loose easily. Reversing the clamp to the front of the flywheel, and bearing onto the frame (lead sheet again) got the retaining nut loose, and bearing against the locking ring, drew the flywheel easily off it's taper, after I had given it a couple of sharp taps on the circumference to break the taper.
IMG_4557 by
bancquoHaving forgotten the existence of this thread, I had to 'reinvent the wheel' and guess the smaller size of belt required. I went for 637mm (25") and a 10mm width cogged type (XPZ637).
IMG_4556 by
bancquoWhen I first put it on, I couldn't get it over my ;pulley, which is about 72mm outside diameter, even with the adjusting bolt removed. However, I discovered that the clutch cable, which is routed below the body of the Dynastart, was preventing it from lowering to the casing. After removing the cable, I managed to get the belt on, and job done. Next is to replace the hideous and dangerous solenoid that the previous owner had fitted below the tank, with exposed terminals, horrible wiring, and all tied up with an inner tube and tape... Also want to fit a fuse between battery and the main power lead, as of course there is no protection at all, and a short could lead to a fire. Does anyone know the maximum current drawn by the Dynastart? I read somewhere that they may be rated at 900W, so the maximum current would be about 75A?