11. ALTERNATOR/STARTER CLUTCH -...

11-1

11

11. ALTERNATOR/STARTER CLUTCH

COMPONENT LOCATION ························ 11-2

SERVICE INFORMATION ························· 11-3

TROUBLESHOOTING ······························· 11-3

STATOR REMOVAL ································· 11-4

FLYWHEEL/STARTER CLUTCH ·············· 11-6

STATOR INSTALLATION ······················· 11-12

ALTERNATOR/STARTER CLUTCH

11-2


COMPONENT LOCATION

157 N·m (16.0 kgf·m, 116 lbf·ft)


11-3

SERVICE INFORMATIONGENERAL

• This section covers service of the alternator stator and flywheel. All service can be done with the engine installed in theframe.

• For alternator charging coil inspection (page 17-9). • For starter motor service (page 19-6).

SPECIFICATIONS

Unit: mm (in)

TORQUE VALUES

TOOLS

TROUBLESHOOTINGStarter motor turns, but engine does not turn • Faulty starter clutch • Damaged reduction gear • Damaged starter idle gear

ITEM STANDARD SERVICE LIMIT

Starter driven gear I.D. 37.000 – 37.025 (1.4567 – 1.4577) 37.10 (1.461)

O.D. 57.749 – 57.768 (2.2736 – 2.2743) 57.73 (2.273)

Starter clutch outer I.D. 74.412 – 74.442 (2.9296 – 2.9308) 74.46 (2.931)

Flywheel bolt 157 N·m (16.0 kgf·m, 116 lbf·ft) Left hand threadApply engine oil to the threads and seating surface.

Stator bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply locking agent.

Starter clutch torx bolt 30 N·m (3.1 kgf·m, 22 lbf·ft) Apply locking agent.

Stator wire holder bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply locking agent.

Flywheel holder07725-0040001

or equivalent commercially avail-able

Rotor puller07733-0020001


11-4

STATOR REMOVALRemove the following:

– Left front side cowl (page 2-9)– Under cowl (page 2-13)– ECM (page 5-77)– Heat guard plate mounting bolt (page 2-23)– Drive sprocket cover (page 7-4)

Remove the bolt, bolt/washer, nut and trim clip(XL700VA only).Remove the ECM stay.

Release the wire harness from the wire band andharness clamp.

Disconnect the alternator 3P (Natural) connector.

Release the alternator wire from the wire guide.

Remove the reserve tank mounting bolt and movethe reserve tank slightly.

Alternator wire pass through the between reservetank and frame.

STAY NUT

CLIP (XL700VA)

BOLT/WASHERBOLT

3P (NATURAL) CONNECTOR

WIRE BAND HARNESS CLAMP

WIRE GUIDE ALTERNATOR WIRE

BOLT

ALTERNATOR WIRE


11-5

Loosen the bolts in

a crisscross pattern

in several steps.

Remove the bolts and left crankcase cover.

• The left crankcase cover (stator) is magneticallyattracted to the flywheel, be careful duringremoval.

• Be careful not to damage the alternator covermating surface.

• Engine oil will run out when the alternator coveris removed. Set a oil pan under the engine andadd the recommended oil to the specified levelafter installation.

Be careful not to

damage the mating

surface.

Remove the dowel pins and clean off the sealantfrom the mating surface.

Remove the bolt and stator wire holder from the leftcrankcase cover.

Remove the wire grommet.

Remove the bolts and stator from the left crankcasecover.

LEFT CRANKCASE COVER

BOLTS

DOWEL PINS

BOLT

HOLDER

GROMMET

BOLTS

STATOR


11-6

FLYWHEEL/STARTER CLUTCHFLYWHEEL REMOVAL

For alternator

charging coil

inspection (page

17-9).

Remove the left crankcase cover (page 11-4).

Remove the starter reduction gear and shaft.Remove the starter idle gear and shaft.

The flywheel bolt

has left hand

thread.

Remove the flywheel bolt and washer while holdingthe flywheel using the special tool.

Remove the flywheel using the special tool.

Remove the washer and needle bearing and woo-druff key from the crankshaft.

• When woodruff key removal, be careful not todamage the key groove and crankshaft.

• Do not lose the woodruff key.

REDUCTION GEARIDLE GEAR

SHAFTS

TOOL:

Flywheel holder 07725-0040001 or equivalent commer-cially available

BOLT/WAHSER

FLYWHEEL HOLDER

TOOL:

Rotor puller 07733-0020001

ROTOR PULLER

FLYWHEEL

WOODRUFF KEY

NEEDLE BEARING

WASHER


11-7

STARTER IDLE/REDUCTION GEAR INSPECTION

STARTER IDLE GEAR/SHAFT

Check the starter idle gear and shaft for wear ordamage.

STARTER REDUCTION GEAR/SHAFT

Check the starter reduction gear and shaft for wearor damage.

STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL

Check the operation of the one-way clutch by turn-ing the starter driven gear.You should be able to turn the driven gear counter-clockwise smoothly, but the gear should not turnclockwise.

Remove the starter driven gear from the flywheelwhile turning the driven gear counterclockwise.

IDLE GEAR

SHAFT

REDUCTION GEAR

SHAFT

DRIVEN GEAR

FLYWHEEL


11-8

Remove the torx bolts while holding the flywheelusing the special tool.

Remove the clutch outer and one-way clutch fromthe flywheel.

STARTER CLUTCH INSPECTION

NEEDLE BEARING

Check the needle bearing for abnormal wear ordamage.

ONE-WAY CLUTCH/CLUTCH OUTER

Check the one-way clutch sprag for abnormal wear,damage or irregular movement.

• Do not remove the one-way clutch from theclutch outer, unless it is necessary to replacewith a new one.

• If the spring is removed from the one-way clutchgroove, replace the one-way clutch assemblywith a new one.

Check the clutch outer for wear or damage.

Measure the clutch outer I.D.

TOOL:


TORX BOLTS

FLYWHEEL

ONE-WAY CLUTCH

CLUTCH OUTER

NEEDLE BEARING

SERVICE LIMIT: 74.46 mm (2.931 in)

ONE-WAY CLUTCH

CLUTCH OUTER


11-9

STARTER DRIVEN GEAR

Check the one-way clutch sprag contact surface,teeth and sliding surface for wear or damage.

Measure the driven gear O.D.

Measure the driven gear I.D.

STARTER DRIVEN GEAR/STARTER CLUTCH INSTALLATION

Clean and apply engine oil to the one-way clutchsliding surface.Install the one-way clutch into the clutch outer withits flange side facing the flywheel.



ONE-WAY CLUTCH

DRIVEN GEAR

CLUTCH OUTER

30 N·m (3.1 kgf·m, 22 lbf·ft)

FLYWHEEL

ONE-WAY CLUTCH

CLUTCH OUTER


11-10

Install the clutch outer and one-way clutch to the fly-wheel.

Hold the flywheel using the special tool.

Clean and apply a locking agent to the torx boltthreads (page 1-18).Install and tighten the torx bolts to the specifiedtorque.

Install the starter driven gear to the flywheel whileturning the driven gear counterclockwise.

Recheck the one-way clutch operation (page 11-7).

FLYWHEEL INSTALLATION

Apply engine oil to the needle bearing and install itto the crankshaft.Install the washer to the crankshaft.Wipe any oil off the mating surface of the crankshaftwith flywheel and woodruff key groove.

Install the woodruff key to the key groove of thecrankshaft.

FLYWHEEL

CLUTCH OUTER/ONE-WAY CLUTCH

TOOL:


TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)

TORX BOLTS

DRIVEN GEAR

FLYWHEEL

During woodruff

key installation, be

careful not to

damage the key

groove or

crankshaft.

WOODRUFF KEY

NEEDLE BEARING

WASHER


11-11

Wipe any oil off the mating surface of the flywheelwith crankshaft.Install the flywheel to the crankshaft, aligning its keygroove with the woodruff key.

Hold the flywheel using the special tool.

Apply engine oil to the flywheel bolt threads andseating surface.

Install and tighten the flywheel bolt with the washerto the specified torque.

Apply engine oil to the starter reduction gear andstarter idle gear shafts outer surface.Install the starter reduction gear, idle gear andshafts to the left crankcase as an assembly.

Install the starter reduction gear with its "OUT" markfacing out.

Install the stator and left crankcase cover (page 11-12).

FLYWHEEL Align

TOOL:


The flywheel bolt

has left hand

thread.TORQUE: 157 N·m (16.0 kgf·m, 116 lbf·ft)

FLYWHEEL HOLDER

BOLT/WAHSER

REDUCTION GEAR

SHAFTSIDLE GEAR

"OUT" MARK


11-12

STATOR INSTALLATION

Install the stator to the left crankcase cover.Clean and apply a locking agent to the bolt threads(page 1-18).Install and tighten the stator bolts to the specifiedtorque.

Install the grommets into the groove in the leftcrankcase cover.

Clean and apply a locking agent to the bolt threads(page 1-18).Install the wire holder to the left crankcase cover.Install and tighten the bolt to the specified torque.

STATOR


WIRE HOLDER

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)


BOLTS

STATOR


BOLT

HOLDER

GROMMET


11-13

Clean off the sealant from the left crankcase covermating surface.

Apply liquid sealant (Three Bond 1207B or equiva-lent) to the left crankcase cover mating surface.

Install the dowel pins.

The left crankcase

cover (stator) is

magnetically

attracted to the

flywheel, be careful

during installation.

Install the left crankcase cover.

Clean and apply locking agent to the bolt threads asshown.

Install and tighten the left crankcase cover bolts in acrisscross pattern in several steps.

Route the alternator wire between the reserve tankand frame.

Install and tighten the reserve tank mounting bolt.

Do not use an

organic solvent

when wiping off the

excessive sealant.

DOWEL PINS


BOLTS BOLT

BOLT

ALTERNATOR WIRE


11-14

Install the alternator wire to the wire guide.

Connect the alternator 3P (Natural) connector.

Install the alternator wire to the wire band and har-ness clamp.

Install the ECM stay and trim clip (XL700VA only).Install and tighten the nut, bolt/washer and boltsecurely.

Install the following:

– Drive sprocket cover (page 7-13)– Heat guard plate mounting bolt (page 2-23)– ECM (page 5-77)– Under cowl (page 2-13)– Left front side cowl (page 2-9)

Check the engine oil level (page 3-12).

WIRE GUIDE ALTERNATOR WIRE

Route the wire

harness properly

(page 1-21).

3P (NATURAL) CONNECTOR

WIRE BAND HARNESS CLAMP

STAY NUT

CLIP (XL700VA)

BOLT/WASHERBOLT

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