The incoming Mini Comtesse has been put to the garage to resolve some issues.
It has been unused for a few years but a quick service got it going. It was willing enough going up and down the lane, but continually seemed to be getting too hot, or stalling. Eventually the electrics began to draw a lot of current and driving in the dark become next to impossible. All a bit odd
So it was pretty clear there was a electrical drain somewhere. A check of the system revealed a pair of over spec halogen bulbs in the headlights. So that was draining the system, in use. Removing the blower wheel and casing from the Sachs 47cc unit allowed a view of the starter unit. I slid out the brushes to isolate the live circuit. Immediately I could see the problem. One of the stator coils was shorting, sending puffs of smoke out, each time the starter button was pressed.
So off with the Motoplat Spanish made unit - not the expected Bosch. This is held on by only three set screws. An unhappy arrangement. It was pretty clear someone had been here before. On one of the set screws the shrunk wrapped plastic insulation had become caught in the threads and had unscrewed itself leaving bare some 5mm of bare steel the other end. It was here the unit was shorting as the coils have only shellac and are hard against the set screws. A poor design.
I managed to reposition the insulation, but switched the set screws round as one was a much less tight fit, the bad one went there. The coil itself showed little damage and I added some insulation, tied on with cotton and doped with some shellac. Pigging difficult with my sausage fingers at the other end of a closed cylinder! My collection of tweezers and probs once again paid their dues.
The unit was put back together and we had integrity of circuits. However now the starter struggled to turn. Taking it off again it was clear that the commutator had been rubbing on part of the stator. Here some fiddling revealed that this unit has no way of locating it centrally that I could find then. With three set screws it is all to easy to be off centre. However despite that the commutator, presumably mounted on a taper, did not look like it was centred. A pencil held across showed a slight eccentric rotation. I am at a loss to understand how that has happened but only removal will eliminate the possibilities. Dirt on the taper, the wrong key in the keyway, or a bent crank or commutator! Experience has taught me not to discount some Herbert in here with a big hammer.
As a test of the rest of the car I put it back together. The play in the stator mount was such I could create enough room for the unit to work fine, but with the brushes moving a lot, sparking. The car ran up but we then ran into some fuelling dramas. This was an issue to resolve later, so that is where work stopped. I need to get the commutator off the crank to see if I can get it to fit and have the assembly central. I feel sure there should be a couple of dowels or a flange to place the stator firmly in the correct place. If not these later engines are not as good a quality as the earlier ones. Seems unlikely.
For the rest of the car there have been some tidying of wire ends, earthing and such. The speedo does not work the Huret speedo. Not looked at that yet. This version has never had waist lights, nor pedal power. Sadly its lost the original rear lights, but the replacements use the same holes, I think. Given supply, an easy reversion to original. Less certain about the headlights. Not sure what was the original fitment, maybe only the bulbs were changed. Brilliantly the wiper motor retains its hand switch on the end, but is wired to a remote switch too. So it can be turned off twice!.
The cycleparts, brakes and steering show minimal wear and overall its in very good condition, no damage, green interior in perfect order. I had to rebuild the locking double door lock. Who ever put it together last time had assembled it to work backwards, thus the tab that locks the bezel had been able to fall sideways slightly and no longer was the cam on the end of the lock able to rotate it fully. Easy mistake to make and I bet others have done the same. Its a weak handle design on that door and I can imagine it being a nuisance. The ordinary door only locks from the inside. I think both are borrowed from Citroen.
Once I have resolved the car back to working, it will be available to a buyer. It has its 1975 registration already, so £17 or tax free next year, as its a 3 wheeled Moped class. Perfect for under-age driving too. Light enough to restrict the speed and use as a pavement mobility car. Goes very well. with more to come I think. Not sure tuning is plum. The auto box changes beautifully and holds gear on demand. Not seen a better one and this one should sell on the button, ready to go.