yea, im stumped too. The only thing new about this is the damper...
I'll do a short vid of the unit as it is, pull it apart, and then put it together again. See if anyone notices anything obvious that I am missing...

 

Hey Stu,

Thats got me puzzled too as I didn't have that prob when doing mine.

You could try sitting the dampers side by side and make sure the inside shafts are the same.
They do slide and the plates etc inside have teeth that line up on the splines. Maybe they're not lining up at the end and its sticking out a bit far.

????

 

thanks Barry. No, both dampers are identical.Each are exactly the same height.I think my problem is the unexpected disassembly of the alternator. I've put it back together as per the diagram, but it still isn't right.

Can you remember if the "flywheel" on the alternator is in or out of the housing?

 

Best I can do, Stu

 

looks nothing like mine. I'll go and try it out.

 

well, if I don't have any washers on the shaft, it would work...?? but I'm guessing there is a reason for the washers
Bugger. I think I'm going to have to take it to the bikeshop...

[IMG]local://upfiles/31617/4DC103CA4B3B4637BD25786277E6CF0D.jpg[/IMG]

 

actually, it didn't work
Just to test a theory, Iput the alternator back in.Just the shaftonly (no damper, washers, collars etc).
It still doesn't even reach the other side...

confused now. I think I'll just leave it for the pros.

Thanks for all your feedback on this problem.

 

With that last pic, is the alt housing completely home against the crankcase?
I do remember it needing a bit of GENTLE force to get home to put the nut on.

Hope that helps.

 

Just another thought.... Have you bent the tab back in??? Maybe thats whats holding it out.....

 

LOL, yes the tab was bent back in...Anyway, problem resolved.

As I was putting the alt back in, wiggling and jiggling to get it through the damper and the hole in the engine casing, I should have noticed that the alt case and that big lump of metal werent going forward. In fact, as the case was going into position, that big ol shiny lump of metal was going backwards. What I should have done originally is to simply tap the shaft in as I had the socket on the end of it, until the socket popped out the end.

I was stumped for so long until I realised that the only thing that could be changed was the one part that I thought was completley rigid and unmoveable all along.

So its on, but the problem remains. Still sounding like a sick dog. Of course, I've probably been a right numpty and put the old damper back on again. I've moved so many parts around to check things that it is likely I have mixed up these two identical parts.

So Bazzman, I can't remember, but I think the middle part of the damper you sent me could spin around quite freely?
I know the one thats now in the bike was quite tight.

I am so looking forward to doing this all again...