Ok, managed to get a new alternator cover, gasket, bolts, oil and filter for about £120 today. Will fit and update soon.

 

Well, now you know how a lathe works... lol. You can tell that someone clearly had been in there before with all that gasket sealer on it. If the sealing surfaces are in good shape after you get the old gasket off, you should not need to put any sealer on it. Honda only puts a small dab of silicone sealer where the rubber grommet goes through the cover. The Stator bolts only get 12 N m of torque, remember it's going into aluminum. A little thread lock might be in order on those bolts.

Is that a bolt broken off in the upper left ?


I realize that we drive on a different side of the road over here , but most of us would say that the Alternator is on the Left side of the bike. Seems interesting that the sound was coming from the right side of the bike. LOL, it's all good. I'm just poking at ya. I'm glad you were able to find the problem and get it sorted out. Good thing there's no damage to the flywheel, that's a very expensive part.

 

Yeah sorry, it was the right hand side I was just being a girl!

Still got problems!!!!



Fitted all the new parts
And it's still making the same
Noise!!! How is that possible.
I've stripped it allllll down again, annoying!
And now I've noticed this...


Is this the cause of my issues, what else could be making the noise so bad?

And no, it isn't a sheered bolt, it was just a glob of that red sealant

 

That large round drum looking thing is the Flywheel which is item #2 located here. The Flywheel is attached to the end of the Crankshaft so it spins rapidly to say the least. It also has really powerful magnets embedded in it. Any metal particles are going to be attracted to it, like bits and pieces of the bolts that got ground away earlier. All of those particles have to be removed. That Flywheel has a really close tolerance fit to the Stator. I suspect that the particle you see in your photo is hitting the Stator which is not good. You should look it over closely.

 

Hi, thanks for the response.
That isn't a metal particle from the bolts.Its part of the flywheel. the stator has been rubbing against it all the way around, if you look at the photo again you can see where it has been rubbing, that picture is the flywheel as clean as i can get it. it isnt dirt, thats damage to the flywheel...

 

Also, after clicking the link that you put in that reply.
I realise that there was NO part 1 or 6 when i removed my cover....

Does this mean the person that went in there before me, didnt put them back on, in turn causing me an issue, or that they have come off and gotten lodged in there somewhere?!?

 

Oh man, sorry to hear it's damaged like that. It's probably hitting the Stator as it rotates around. Going to need to replace it for sure. I can see the threads in the hole where Items 1 and 6 would go in one of your photo's and it doesn't look damaged. I suspect that it was just left out by the previous person.

Yes, someone has been in there before for sure. All that red sealant is not factory at all. Honda applies a small dab of clear silicone sealant near the part where that black rubber grommet for the wiring harness goes through the cover. No other sealant is needed if the mating surfaces of the engine case and the Alternator cover are in good condition. Make sure you're using a torque wrench to tighten the cover bolts.

Luckily you can get a Flywheel from ebay for less than $50 US, not sure what it would be there in the UK, but they seem to be readily available.