MK III alternator wire chewed through

Hello all,

I just installed a new Tri Spark in my MKIII and it works great. While out on a test run my assimilator light came on. Took the primary cover off and found the alternator wire chewed through. I was going to splice the wires, solder them and use heat shrink tubing unless someone can suggest an alternate idea. I was wondering what the correct position for the stator was in regards to the wire position. 4 O'clock? Also, would appreciate any comments about using gasket cement on the primary. Thanks.

nberg said:

I was wondering what the correct position for the stator was in regards to the wire position. 4 O'clock?

Click to expand...

Yes http://www.classicbike.biz/Norton/Repai ... mmando.pdf
(Section C, Fig. C49)

nberg said:

Also, would appreciate any comments about using gasket cement on the primary.

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Do you mean in addition to, or in place of, the MkIII primary gasket?
If the gasket surfaces are in good condition, then a greased standard gasket should be all that's required.

L.A.B. said:

nberg said:

I was wondering what the correct position for the stator was in regards to the wire position. 4 O'clock?

Click to expand...

Yes http://www.classicbike.biz/Norton/Repai ... mmando.pdf
(Section C, Fig. C49)

nberg said:

Also, would appreciate any comments about using gasket cement on the primary.

Click to expand...

Do you mean in addition to, or in place of, the MkIII primary gasket?
If the gasket surfaces are in good condition, then a greased standard gasket should be all that's required.

Click to expand...

Fig C49 on that link doesn't show the Stator and wire position. I think it is a link to the wrong manual, It's not the Mk3 one, but I can't fix that.

Old Bloke said:

Fig C49 on that link doesn't show the Stator and wire position. I think it is a link to the wrong manual, It's not the Mk3 one, but I can't fix that.

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My apologies, correct MkIII manual link: http://britmoto.com/manuals/Manuals/850_man.pdf

Ive had a simular problem.
I wrap a piece of wire around one of the 3 studs & tighten it under the nut.
Then I wrap the other end around the wires to keep them in place so it does not move & rub against the belt on the belt drive.
Cheers Don

Here are three images of the wire position from what appears to be the original routing. Perhaps they may be useful.
I cannot attest to originality as a PO has been in here to service the sprag assembly but it all looks reasonable.
BTW the black sleeving in the photo's is quite stiff at room temp, likely the result of exposure to hot oil and age.
I would suspect new sleeving to be more flexible.
Application of gasket cement may complicate subsequent cover removal.
Perhaps if the cement was applied to the surface most easily cleaned, ie the outer cover itself has no protruding dowels, and a light greasing on the other side, then removal may be easier and the gasket may remain in one reuseable piece.

HARNESS IS SHOWN ON THE WRONG SIDE OF THE STATOR


HARNESS IS SHOWN ON THE WRONG SIDE OF THE STATOR


HARNESS IS SHOWN ON THE WRONG SIDE OF THE STATOR


If the chain is chafing the harness then I believe you can adjust the sleeve length inside the primary as needed by pushing or pulling the sleeving through the exit grommet as a means to increase the chain to harness clearance, this may be difficult if one has employed silicone sealer inside the grommet.
Wonderfully complex inside the MKIII primary. It makes me smile.
All the best.

05012013 edited to include enlarged photo with embedded text below

HARNESS IS SHOWN ON THE WRONG SIDE OF THE STATOR


the more thought I give to the others statements about the stator being "flipped" the more uncomfortable I am with the wires being squished. Although working normally this is not proper and will be corrected at the earliest opportunity.
The additional photo with the text embedded is offered to help anyone else who may have the question.
The photos posted DO NOT SHOW THE CORRECT WIRE POSITION and have been captioned as such so as not to mislead.
All the best.

AntrimMan said:

Here are three images of the wire position from what appears to be the original routing. Perhaps they may be useful.
I cannot attest to originality as a PO has been in here to service the sprag assembly but it all looks reasonable.

Click to expand...

I think the stator is normally fitted so the wiring is on the outside.

Hi I agree with the last guy. Mine has always had the wire on the outside from new and its nowhere near as close to the chain as yoursmm give it a try with the wire on the outside and see if the chaincase cover goes on. If it still does up then there will be much less chance of it rubbing. Cheers don

L.A.B. said:

I think the stator is normally fitted so the wiring is on the outside.

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now THAT"S enlightening. I would never have given it a second thought since it's all working properly so far.
This is the first time I have had the cover off this one and now I wonder how long it's been like that.
Like our man from Arkansas stated, " a used motorbike is like a box of chocolates" credit Hobot.
Thanks for the comments gents.
All the best.

05012013 edited to note correction to prior post.
Sorry about the innocent error above and a big thanks to those who noticed it.
The prior post has been edited to avoid being misleading.
All the best.