MKIII Primary chain noise

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Classic Cycle Repair said:
The chain can not reach the cable, as the tensioners cannot travel that far.

But that is not the issue. The cable must exit outwards to avoid being trapped between the stator body and the mounting bracket.

You have the inner side of the stator facing out. The side with the cable exiting faces out.

You should be able to just draw the cable through somewhat, and flip the stator.

Are the washers behind those stator nuts? I cannot tell from the pic if they are the correct "7/16 af" type.
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The cable exits the stator here and doesn’t look trapped or pinched. Is this the concern?
Again, I assumed this to be normal as it is how I removed it. I do see in the manual now it was originally the other way.

MKIII Primary chain noise



MKIII Primary chain noise
 
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Classic Cycle Repair said:
The damage to the stator has already occurred. The incorrect fitment has forced the cable down, and broken away the insulation.
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Must be that I’m just not familiar enough with what this insulation should look like. When the stator was off and looking at the area where the wire exits the stator, I didn’t notice any cracks in the black sheath covering the wires nor see any cracks/damage or indication of any issues on the epoxy covering surrounding the stator wires.
 
CR125Honda said:
Must be that I’m just not familiar enough with what this insulation should look like. When the stator was off and looking at the area where the wire exits the stator, I didn’t notice any cracks in the black sheath covering the wires nor see any cracks/damage or indication of any issues on the epoxy covering surrounding the stator wires.
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The wires normally exit from the (outer) face of the stator (see below).
For the wires to be in the position in your photo the thin wall of epoxy at the periphery has probably broken due to the wires being flattened by the outrigger plate.

MKIII Primary chain noise
 
MKIII Primary chain noise
...but, it kinda looks OK, like pattern part, wires maybe exits O.D.?
 
L.A.B. said:
The wires normally exit from the (outer) face of the stator (see below).
For the wires to be in the position in your photo the thin wall of epoxy at the periphery has probably broken due to the wires being flattened by the outrigger plate.

MKIII Primary chain noise
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Got it. That visual make’s it easy to understand.
As I recall, there’s a rubber grommet protecting the wiring sheath where it exits the internal metal housing. The edges of the epoxy on both sides of the wire looked straight with flat edges. Without thinking about it much, I assumed it was made that way. Will inspect closer when I get back to this next week. Thanks so much to both of you for pointing this out!
 
Back at it.
After pulling it off, it was easy to see I had not really looked at that area too closely.
Became obvious the insulation was missing.
Pulled the wire through to allow the flip, resealed, etc..
No cracks in sheath, frayed or exposed wires, etc.
As far as I know, it was re-charging the battery when installed backwards.
Should also charge as it's installed correctly now.

Thanks again for pointing this out! Much appreciated.

MKIII Primary chain noise
 
CR125Honda said:
Back at it.
After pulling it off, it was easy to see I had not really looked at that area too closely.
Became obvious the insulation was missing.
Pulled the wire through to allow the flip, resealed, etc..
No cracks in sheath, frayed or exposed wires, etc.
As far as I know, it was re-charging the battery when installed backwards.
Should also charge as it's installed correctly now.

Thanks again for pointing this out! Much appreciated.

MKIII Primary chain noise
Click to expand...
It looks like your large circlip retaining ring that holds the clutch diaphram in the clutch basket isn't in the groove on the top of the clutch basket in your photo. It will come apart if it isn't completely seated all the way around in the clutch basket groove.
 
Nortarly said:
It looks like your large circlip retaining ring that holds the clutch diaphram in the clutch basket isn't in the groove on the top of the clutch basket in your photo. It will come apart if it isn't completely seated all the way around in the clutch basket groove.
Click to expand...
Thanks Nortarly,
While installing it, seeing the shiny portion of the clip bugged me.
It had a shiny part on the ring on both sides.
Just checked pics before disassembly and it shows the same.
Thought I checked pretty closely when installing that it went fully in the groove.
Guessing the clutch has been disassembled a few times, cir-clip installed both ways, and the shiny portion of the clip your seeing (which is uniform all the way around) is where the diaphragm (pressure plate) contacts the ring.
 
CR125Honda said:
Guessing the clutch has been disassembled a few times, cir-clip installed both ways, and the shiny portion of the clip your seeing (which is uniform all the way around) is where the diaphragm (pressure plate) contacts the ring.
Click to expand...

Yes, it's a rub mark made by spring.
MKIII Primary chain noise
 
Nortarly said:
It looks like your large circlip retaining ring that holds the clutch diaphram in the clutch basket isn't in the groove on the top of the clutch basket in your photo. It will come apart if it isn't completely seated all the way around in the clutch basket groove.
Click to expand...
Good observation. I use a flat head punch to tap all around the giant circlip to make sure it's all fully home before releasing the clutch compressor tool. No accidents allowed.
 
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