cracked rotor, Belleville washers, and upgrade questions

I'm the original owner, 1974, so it came to me with the Belleville washers mod from new. I'm going back with an RM23 and it's rotor will need the star washer,(on order) and had a couple questions:
--Stator has two green/yellow wires....problems?
--replacing stock unit with a180w rectifier...is that all that's needed?

openroad said:

--Stator has two green/yellow wires....problems?

Click to expand...

No, as it's AC (although they would usually be green/yellow and white/green).

openroad said:

--replacing stock unit with a180w rectifier...is that all that's needed?

Click to expand...

Assuming you mean regulator/rectifier then yes. If not, we need more information.

"a Lucas single phase rectifier, (part # 49181)" is what I ordered.

Looking further I guess adding another zener diode may be needed? Whoa, just saw the price for that!

openroad said:

"a Lucas single phase rectifier, (part # 49181)" is what I ordered.

Looking further I guess adding another zener diode may be needed?

Click to expand...

Yes, as it's the 'regulator' part of the charging system that has to be able to cope with the additional output, so two Zeners are normally required for the RM23. These can be an unmatched pair if connected according to the diagram below (standard Mk3 charging layout).

openroad said:

Whoa, just saw the price for that!

Click to expand...

It's often cheaper to buy a reg/rec unit.
http://www.podtronics.net/

="openroad"snipped I'm going back with an RM23 and it's rotor will need the star washer,(on order) and had a couple questions:
--Stator has two green/yellow wires....problems?
--replacing stock unit with a180w rectifier...is that all that's needed? snipped

Click to expand...

I believe you will also need a second Zener diode & a slight modification to your wiring. I would suggest you study the charging system schematic for the Mk 3 and duplicate it's charging system wiring. Contact me off list if you need a copy of that schematic. I can not post this file, as I'm not a VIP member. Photobucket will not accept non image files, like PDFs or DOCs. so I can not host it externally. Looks like Les has provided the needed schematic while I was typing this up.

openroad said:

"a Lucas single phase rectifier, (part # 49181)" is what I ordered.

Looking further I guess adding another zener diode may be needed? Whoa, just saw the price for that!

Click to expand...

Might you have a used 12 volt Zener from another Brit bike kicking around? If so, you can use that. The Mk 3 uses two of the same Zeners Lucas supplied to earlier 12 volt models.

You could switch to a regulator rectifier Podtronics or similar.

Regards

Esme

I may have something out in the Tiger Cub box-o-pieces, but it starting to sound like a Podtronics is in the future. It's all an adventure, isn't it.......

i would go for the podtronics ,all the current replacement Zenors work at a higer voltage 16v and not 14.4v

Installing the rotor and stator from a MKIII into my 1974 and hit these problems:
Shims and spacer in..

The rotor nut bottoms out on the threads before tightening up, the screwdriver tip shows the slop:

At this point the rotor is way not lined up with the stator depth-wise:

The original rotor was sandwiched between two Belleville washers, however the new rotor's timing marks seem to get in the way on the outside, the backside is smooth so I'm wondering if it's OK to use one on the backside to maybe shim it out some, there's just enough room on the inside of the key, in fact it looks like the key wore a spot on the washer already.


None of this shows up in my manuals or diagrams, but I've read of shimming the rotor here on the forums. I haven't mocked it up yet to see the improvement, thought I'd get some suggestions, maybe I'm not seeing something right here.