Alton Starter Alternator Rectifier

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Dear All.
My Setup: Norzon 850 MKII, Rectifier from Boyer Power Box, AGM Battery 20Ah.
The alignment of stator and rotor was checked deeply.
The Alton after a while didn't start the Norton anymore and did a rattling noise.
After the first shock ( I was assuming the Sprag clutch rotor assembly failed) I've been testing Battery.
Voltage break down to 8 V while starting and the Alton doesn't spin the engine and do the rattle noise.
By a new engine start by kicking I've measured the outcome of Voltage was less 12.5 Volt. So I took out the Powerbox and have test it by a 25V AC Power supply. Voltage was no load 14 V.
Which kind of Rectifier is used in your setup?
Anybody use the Powerbox without issues?
Do I overlook something?
Overall I'm really happy with the Alton and I was surprised how powerful the Starter spin up the engine.
Hopefully I will fix the Non-Loading issue of Battery.
Regards Lorenz
 
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I’m not sure from your post if you still have an issue with your Alton.
If the crank nut is torqued and loctighted to Altons current spec and the nylon sheer pins sheer it’s worth changing from fitting the 3 as standard to 4.
I had discussions with Paul.
I have very good compression and had an issue with 3.
4 seems to have fixed the problem.
Also bearing in mind the switch gear is 50 or so years old it can supply insufficient voltage to activate the starter.
I fitted a relay which sorted that problem. I have since fitted NOS switch gear but have retained the relay.
Hope this helps.
 
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Hi. Thank you for reply.
Nylon Pins are OK. No issue at all with them.

--> Also bearing in mind the switch gear is 50 or so years old it can supply insufficient voltage to activate the starter.

Thanks for figure out that 50 eyears old electronic can cause issues, but : No, the electronic is NOT 50 years old! ;)

The question is: Which rectifier have other installed combined with Alton Stator?

Does the Powerbox not work with the ALTON alternator secure?
 
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To my knowledge, Alton recommend only the PODtronics reg/rec.

Truth be told, the Boyer Bransden PowerBox should be ok, as the tech spec is the same.
...however, it is not one that Alton recommend., so I wouldn't risk it.
 
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The powerbox has an equivalent to a 2MC capacitor inside, same issues with failure of the Lucas 2MC and it can effect the rest of the box dependant on the way it fails.
 

baz

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Hi. Thank you for reply.
Nylon Pins are OK. No issue at all with them.

--> Also bearing in mind the switch gear is 50 or so years old it can supply insufficient voltage to activate the starter.

Thanks for figure out that 50 eyears old electronic can cause issues, but : No, the electronic is NOT 50 years old! ;)

The question is: Which rectifier have other installed combined with Alton Stator?

Does the Powerbox not work with the ALTON alternator secure?
Alton recommend the podtronics unit
I was using one on mine but I accidentally shorted it out and destroyed it
I changed it to a Honda reg/rectifier using two of the 3 phase wires and it works perfectly with the Alton
 
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I've been using the Podtronics since '12, when I installed the Alton starter/alternator. It's been trouble free although it provides around .2VDC LESS charging voltage than the OEM Lucas did with the Alton system. :rolleyes:
 
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To my knowledge, Alton recommend only the PODtronics reg/rec.

Truth be told, the Boyer Bransden PowerBox should be ok, as the tech spec is the same.
...however, it is not one that Alton recommend., so I wouldn't risk it.
By the other replies it seems that the issue on non-loading battery is combination Powerbox / Alton!
So I have ordered now the PODTRONIC
Thank you all for the friendly help and fast replies!
Appreciated!
 

baz

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By the other replies it seems that the issue on non-loading battery is combination Powerbox / Alton!
So I have ordered now the PODTRONIC
Thank you all for the friendly help and fast replies!
Appreciated!
What ignition do you have? If you have a trispark I don't think they get on too well with podtronics
Others will hopefully chime in here
 
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What ignition do you have? If you have a trispark I don't think they get on too well with podtronics
Others will hopefully chime in here
Trispark. And happy with that ignition since 5 Years! NO kick Back in all that time.
I remember with horror the times when fancy colored Boyer was in and I feared to kick. :mad:
 

baz

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Derek Wilson

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I have used a 200W PODtronics with mine - I was never really impressed with the power output - could never get more than about 13.6 volts out of it.

I replaced my Boyer EI with a TriSpark earlier in the year, and experienced the erratic missing between 3000-4000 RPM, which is typical of the 200W PODtronics / Trispark combo.

I tried the filter that Trispark recommends, but it did not help - actually caused the PODtronics to not charge at all when fitted as instructed.

Frustrated, I installed a full-wave bridge rectifier and Zener diode - basically reverted to the factory fitted arrangement. No issues with missing, and the charging system works better than ever. I now see full operating voltages of 14.4-14.5. Works very well with my Shoria battery.

I have still had my Alton start my bike with a battery voltage in the 11's. It laboured a bit, but it cranked. If you are hearing a rattling sound, I'd be checking the overload device. Mine recently sheered, and I filled all 6 slots when I addressed it. Like yours, my engine never fights the starter (no kickback's etc.), so I felt safe doing this.

FWIW
 
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If you are hearing a rattling sound, I'd be checking the overload device. Mine recently sheered, and I filled all 6 slots when I addressed it.

FWIW
Rattling sound disappears once I start the bike with support by a second Battery!

Enough Amps and Voltage = enough torque to move the lovely parallel twin!
 
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You need to check the output of the Alton alternator. With the alternator disconnected you should get over 20v AC output on the two wires from the alternator at a fast idle speed. Mine dropped to less than 10v due to the magnet ring losing strength. I had to buy a new magnet ring and have no idea why the old one failed after 2 1/2 years of being ok.
 
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Derek Wilson

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You need to check the output of the Alton alternator. With the alternator disconnected you should get over 20v AC output on the two wires from the alternator. Mine dropped to less than 10v due to the magnet ring losing strength. I had to buy a new magnet ring and have no idea why the old one failed after 2 1/2 years of being ok.
My magnet ring (rotor) was weak right out of the box - replaced under warranty within the first month.
 
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You need to check the output of the Alton alternator. With the alternator disconnected you should get over 20v AC output on the two wires from the alternator. Mine dropped to less than 10v due to the magnet ring losing strength. I had to buy a new magnet ring and have no idea why the old one failed after 2 1/2 years of being ok.
Voltage output alternator direct was the only thing I didn't check honestly.
I will do this by this evening.

Normally only two reasons responsible for dis-magnatizing: - Extremly Temperature and / or extremly Vibrations!
Or does the magnet grind at the aternator ring? This could also a reason.
Strange.
My magnet ring (rotor) was weak right out of the box - replaced under warranty within the first month.
WOW!!!!
That is not good!

OK, for sure I will check the outcome of AC by the alternator of ALTON.
Will let you know tomorrow.

What a great forum what kind answers! Im impressed about your help and friendly feedback!
 

cliffa

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I have the Alton with a Boyer Power Box, no issues so far. Are you sure that battery is not breaking down under load?
 
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I have the Alton with a Boyer Power Box, no issues so far. Are you sure that battery is not breaking down under load?
100 % sure. Batterie is in new. I have measured the outcome voltage of Boyer Power Box while motor runs. Nothing! Tested the Boyer at 24AC power supply it works. Even connected to the Batterie and 24V AC gives approx. 14 V DC load . Today it was late and I didn’t finish my work. 200 Watt Podtronics arrived today thanks Dieter Cordes. Tommorow hopefully everything works.
 

maylar

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Wait -

If the Boyer works when connected to an AC source, it should also work on the motorcycle. You should be looking at the alternator, not the regulator.
 
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