Hi Miles;
You're right, a hammer was not my choice of tools for this job. Really.
Bill
Re: [2cylinderhondas] Valve Springs/Valves Removal
Honda 600 latest in electrical problems - think safety
Harry Lineback and I had a problem with a AN600 this weekend I thought was
worth sharing.
Situation: The 72 AN600 was running but had a oil burning problem.
Trouble shooting indicated oil getting past the rings. Engine was removed
and cylinders/pistons were replaced. Engine was reinstalled, but, then would
not start.
Symptoms: 1. The battery discharged in minutes.
Recharged the battery and, the battery was new.
2. The Starter dragged, everything
looked ok, but removed the electrode end of the solenoid and cleaned the
contacts.
3. While trying to start the engine,
wisps of smoke came from the ground wire leading to the stator brushes.
Correction: 1. We pulled the wire harness connecting the
brushes, starter and stator to the voltage regulator and ignition harness.
Unwrapped all the wires and repaired the ground wire connection which had
melted, but really didn't show any wear or indication any of the wires
caused the problem.
2. Next we pulled the brushes from
the stator, here we found more wire insulation melting on the Negative side
of the brush assembly. The rubber gasket was warn away and the wire
connection to the negative side had touched the engine case causing a short
in the system.
3. The Stator Brush Assembly was the
problem. Years ago the negative wire had been repaired on the brush
assembly, which although good at the time had caused some insulation
problems. And, while removing or replacing the engine further problems were
caused to the negative wire on the brush assembly which lead to it grounding
out. Repair was to rebuild the brush unit taking care not to cause a short
in the system.
End Result: Car started on first try, starter worked great and plenty of
power.
Note of Caution: All the wires on the Honda 600 cars are getting older
which in this case caused the negative lead to ground out. Rule of thumb,
When ever there is a problem with electrical wires it's best to completely
renew the wires. If correcting electrical problems is new to you; There is
an article in the 1982 October issue of Special Interest Autos (SIA# 71)
from Hemmings Motor News publications, on how to Rebuild a Wire Loom. The
article may still be had by going to www.hemmings.com and sending them an
e-mail requesting a reprint. I have had them bring up old files before. Or
go to www.eastwood.com where there are a number of restoration project help
files included with their products. Also, www.jcwhitney.com has an
extensive How-To book shelf, one "Automotive Electrical Handbook" which
gives a number of alternatives to the old wire problem. Just to name a few.
Safety Tip:
The least that can happen is melted insulation, the worst is a fire in the
electrical system which can start hours after the car is parked in the
garage for the night. If you are having problems with your electrical
system, disconnect the battery until you can work on it again.
Have Fun
Bill
worth sharing.
Situation: The 72 AN600 was running but had a oil burning problem.
Trouble shooting indicated oil getting past the rings. Engine was removed
and cylinders/pistons were replaced. Engine was reinstalled, but, then would
not start.
Symptoms: 1. The battery discharged in minutes.
Recharged the battery and, the battery was new.
2. The Starter dragged, everything
looked ok, but removed the electrode end of the solenoid and cleaned the
contacts.
3. While trying to start the engine,
wisps of smoke came from the ground wire leading to the stator brushes.
Correction: 1. We pulled the wire harness connecting the
brushes, starter and stator to the voltage regulator and ignition harness.
Unwrapped all the wires and repaired the ground wire connection which had
melted, but really didn't show any wear or indication any of the wires
caused the problem.
2. Next we pulled the brushes from
the stator, here we found more wire insulation melting on the Negative side
of the brush assembly. The rubber gasket was warn away and the wire
connection to the negative side had touched the engine case causing a short
in the system.
3. The Stator Brush Assembly was the
problem. Years ago the negative wire had been repaired on the brush
assembly, which although good at the time had caused some insulation
problems. And, while removing or replacing the engine further problems were
caused to the negative wire on the brush assembly which lead to it grounding
out. Repair was to rebuild the brush unit taking care not to cause a short
in the system.
End Result: Car started on first try, starter worked great and plenty of
power.
Note of Caution: All the wires on the Honda 600 cars are getting older
which in this case caused the negative lead to ground out. Rule of thumb,
When ever there is a problem with electrical wires it's best to completely
renew the wires. If correcting electrical problems is new to you; There is
an article in the 1982 October issue of Special Interest Autos (SIA# 71)
from Hemmings Motor News publications, on how to Rebuild a Wire Loom. The
article may still be had by going to www.hemmings.com and sending them an
e-mail requesting a reprint. I have had them bring up old files before. Or
go to www.eastwood.com where there are a number of restoration project help
files included with their products. Also, www.jcwhitney.com has an
extensive How-To book shelf, one "Automotive Electrical Handbook" which
gives a number of alternatives to the old wire problem. Just to name a few.
Safety Tip:
The least that can happen is melted insulation, the worst is a fire in the
electrical system which can start hours after the car is parked in the
garage for the night. If you are having problems with your electrical
system, disconnect the battery until you can work on it again.
Have Fun
Bill