CA77 engine locked up while idling

[Geoff Hastings]

Having reassembled the starter clutch, I rebuilt the two damaged windings on the stator using a couple of donor coils from another stator. While I had the cases off I also pulled the clutch apart as I was not happy with its performance. Turned out that two of the plates were buckled so they were replaced. Once all back together and filled with oil I gave it a couple of spins with the plugs out and as all seemed ok I bit the bullet and fired it up. I then took it for tentative spin round the block and all seems ok. I'm still a bit puzzled as to what caused it to lock up, the only damage I could find was to the stator windings but could not find the cause, unless the foreign body dropped out when I removed the casing? My garage floor was not spotless so it could be one of the odd screws or bolts laying there. I'll keep the rides short till my confidence in the bike returns and obviously, if it shows any signs or unusual noises then I'll just drop the engine out and do a full strip. If nothing else, I now have a clutch that works much better, I can even get neutral when stopped.

[G-Man]

Sounds like progress has been made....

G

Having reassembled the starter clutch, I rebuilt the two damaged windings on the stator using a couple of donor coils from another stator. While I had the cases off I also pulled the clutch apart as I was not happy with its performance. Turned out that two of the plates were buckled so they were replaced. Once all back together and filled with oil I gave it a couple of spins with the plugs out and as all seemed ok I bit the bullet and fired it up. I then took it for tentative spin round the block and all seems ok. I'm still a bit puzzled as to what caused it to lock up, the only damage I could find was to the stator windings but could not find the cause, unless the foreign body dropped out when I removed the casing? My garage floor was not spotless so it could be one of the odd screws or bolts laying there. I'll keep the rides short till my confidence in the bike returns and obviously, if it shows any signs or unusual noises then I'll just drop the engine out and do a full strip. If nothing else, I now have a clutch that works much better, I can even get neutral when stopped.

[Geoff Hastings]

Hi guys, as a follow up to the previous posts the bike now runs well. I've done about 50 miles on it since putting the cases back on. All seems we'll, no strange noises and I've rung its neck a few times on a make or break it test. It would have been nice to have found something definite but in the end I'm just glad it's running and I won't need to fully strip the engine. Just need to sort the fuel tap now, the usual problem of the seals swelling and cutting off the fuel.