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Fast onset terrible noise in Shimano generator hub

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Fast onset terrible noise in Shimano generator hub

Old 09-25-18, 05:43 PM
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Fast onset terrible noise in Shimano generator hub

I've been riding on a Shimano DH-3N80 for 3 1/2 years. Today on my way home I noticed an occasional metallic popping noise coming from my front wheel, accompanied each time by a vibration I could feel in my handlebars. At first it was only apparent when I was on the bike, and seemed to spin smoothly when I stepped off and spun the wheel. I took off the wheel and could tell there was extra play in the hub, and what felt like a roughness in the bearings when I wiggled the axle on the side with the electrical connection that seemed to be the cause of the sound. I rode it another mile home and the noise increased in frequency until it was nearly constant. Does anyone have any idea what could cause this?

I overhauled the hub ~5 months ago. My ride today was very wet. I would compare the sound to riding on a hub with rusty pitted bearings and a broken axle.
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Old 09-25-18, 11:07 PM
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Why don't you take the hub apart again and see the internal condition? Andy
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Old 09-28-18, 10:27 AM
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I'm thinking the generator has an air gap, and that some bit of magnetic steel/iron detritus has dislodged from one part and is intermittently interacting within the air gap.

My battery-powered mower motor has this issue, it makes clicking noises and is enough to reduce the motor's output since the air gap is being closed (which messes with the magnetic field enregy conversion). I will need to take the motor apart.

Can you access the armature assembly?
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