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Page 8-0

Page 8-1

8. ALTERNATOR/STARTER CLUTCH

SERVICE INFORMATION8-1
LEFT CRANKCASE COVER REMOVAL8-2
FLYWHEEL REMOVAL8-3
STARTER CLUTCH8-4
FLYWHEEL INSTALLATION8-5
LEFT CRANKCASE COVER INSTALLATION8-6

SERVICE INFORMATION

GENERAL


SPECIFICATIONS

mm (in)

ITEMSTANDARDSERVICE LIMIT
Starter driven gear O.D.57.747-57.768 (2.2736—2.2743)57.60 (2.268)


TORQUE VALUES


Flywheel bolt130 N•m (13.0 kg-m, 94 ft-lb) Left-hand thread
Starter clutch Torx bolts30 N•m (3.0 kg-m, 22 ft-lb) Apply locking agent to the threads


TOOLS


Common
rotor puller07733—0020001 or 07933—3290001
Flywheel holder07725—0040000Equivalent commerically
avalable in U.S.A.
T-40 Torx Bit07703—0010100

Page 8-2


LEFT CRANKCASE COVER REMOVAL

Disconnect the alternator 3P connector (WHITE)

Remove the gearshift arm pinch bolt and shiftarm from the spindle.

Remove the drive sprocket cover.



Place a container under the left crankcase cover to catch the engine oil.

Remove the eleven left crankcase cover bolts and the cover.



Remove the dowel pins and gasket.



STATOR REPLACEMENT

Remove the wire clamp bolts and the clamps.
Remove the stator mounting bolts and stator.

Position the new stator and the grommets in the cover.
Apply a locking agent to the threads of the stator mounting bolts.
Tighten the stator mounting bolts and the clamp bolts.



Page 8-3


FLYWHEEL REMOVAL

Remove the starter idle/reduction gear by removing the shaft.



Hold the flywheel with the flywheel holder and remove the flywheel bolt and washer.

TOOL:
Flywheel holder07725—0040000 Equivalent commercially available in U.S.A.

NOTE





Remove the flywheel with the rotor puller.

TOOL:
Rotor puller07733—0020001 or
07933—3290001


Remove the needle bearing from the crankshaft, then remove the woodruff key.

NOTE




Page 8-4


STARTER CLUTCH

DISASSEMBLY

Reinstall th starter driven gear into the flywheel.

Inspect the starter clutch by turning the starter driven gear.  The gear should turn counterclockwise freely and should not turn clockwise: if it turns incorrectly, replace the starter clutch.





INSPECTION

Measure the O.D. of the starter driven gear.

SERVICE LIMIT: 57.60 mm (2.268 in)



Inspect the oneway clutch for wear or damage and replace if necessary.


Page 8-5


ASSEMBLY

Install the oneway clutch into the outer with the flange side facing inside.



Hold the flywheel with the flywheel holder.  Apply locking agent to the torx bolt threads and tighten the bolts.

TORQUE: 30 N•m (3.0 kg-m, 22 ft-lb)

TOOLS:
Flywheel holder07725—0040000Equivalent commercially
available in U.S.A.
T-40 Torx bit07703—0010100


FLYWHEEL INSTALLATION

Clean the crankshaft and install the woodruff key.

Install the needle bearing into the crankshaft.



Install the driven gear and flywheel, aligning the woodruff key on the crankshaft with the flywheel keyway.

Hold the flywheel with the flywheel holder, install the washer and flywheel bolt and tighten the bolt.

TORQUE: 130 N•m (13.0 kg-m, 94 ft-lb)


TOOL:
Flywheel holder07725—0040000
Equivalent commercially available in U.S.A.

NOTE



Page 8-6

Install the starter idle/reduction gear with the longer shaft.

Install the starter drive gear with the “OUT” mark facing out and the shorter shaft, if the gear is removed.



Install the dowel pins and new gasket



LEFT CRANKCASE COVER INSTALLATION

Install the left crankcase cover and tighten the cover bolts with the neutral and oil pressure switch wire harness clamps as shown.

Route the alternator wire and connect the alternator 3P connector

Install the drive sprocket cover.



Install the gearshift arm into the spindle by aligning the punch mark on the arm with the punch mark on the spindle

Tighten the gearshift arm pinch bolt.

TORQUE: 12 N•m (1.2 kg-m, 9 ft-lb)

Install the drive sprocket cover.

Check the engine oil level and add the oil if necessary.