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I've finally scraped enough motivation together to strip the generator off of my totally bogus low-mileage RSV engine. If you recall - it only ever ran on the front cylinder and EVERYTHING else checked out... which left one thing which the Griffmeister suggested... the generator has sheared the key and spun on the crankshaft.





20 minutes from actually getting the generator off... my room door locks itself and I can't get to my toolbox for 3 hours until the landlord turns up.

Aaaaaagh.

I did find a small 2mm piece of metal floating around in there - former woodruff key shard.

More to follow, but in the meantime I got a new ride! My dad has just handed on his pride and joy - which I was riding last weekend in France.



Cycling is almost faster but man does it draw attention. I've just got to find somewhere secure for it to live - there might be one other in the UK.

But as ancient Italian metal goes, this stole my heart:

If the stator flywheel has spun then I would imagine that Loctite 648 has not been used if the flywheel had been removed and refitted in the past?

Flywheel of without using heat... it wasn't done up very much - but I see no evidence that it's not exactly as it should be...




Prior to coming off - all seems well



Everything in the same alignment as the key and the key is perfect



Should this not have a washer on it? It wasn't very tight and the outer surface is taking all the load. I can't remember whether there should be one or not from the last engine.



Journal for the key is absolutely fine.

So my last big hypothesis for what's wrong with this seems to have been falsified - can you guys see anything wrong here?

Is there a washer under that bolt? There should be.

Don't forget the Loctite is used on the crank outer surface and inside the stator flywheel and not on the bolt.

No washer at all! There was a massive well of Loctite (it did look green) around the bolt which I'm sure wasn't torqued up and some eveidence it had been on the taper.

If the same person that put this back together also changed the heads (for small valve equivalent) I have to wonder quite how long this POS is going to hold together IF it ever runs again!

Is that washer aluminium? I'm going to have to buy something.

Sorry - not much help here on the guts of the Rotax lump .... furthest I have needed to delve is removing the cam covers to check the valve clearances.

Just to say, that CZ looks excellent - though it should if it's just been through that laundry!

The Gilera is nice too.