11.
ALTERNATOR/STARTER CLUTCH
COMPONENT LOCATION ························ 11-2 STATOR REMOVAL ································· 11-4
SERVICE INFORMATION ························· 11-3 FLYWHEEL/STARTER CLUTCH ·············· 11-6
TROUBLESHOOTING ······························· 11-3 STATOR INSTALLATION ······················· 11-12
11
11-1
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ALTERNATOR/STARTER CLUTCH
COMPONENT LOCATION
ALTERNATOR/STARTER CLUTCH
157 N·m (16.0 kgf·m, 116 lbf·ft)
11-2
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ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
GENERAL
• This section covers service of the alternator stator and flywheel. All service can be done with the engine installed in the
frame.
• For alternator charging coil inspection (page 17-9).
• For starter motor service (page 19-6).
SPECIFICATIONS
Unit: mm (in)
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)
TORQUE VALUES
Flywheel bolt 157 N·m (16.0 kgf·m, 116 lbf·ft) Left hand thread
Apply 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.
TOOLS
Flywheel holder Rotor puller
07725-0040001 07733-0020001
or equivalent commercially avail-
able
TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged reduction gear
• Damaged starter idle gear
11-3
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ALTERNATOR/STARTER CLUTCH
STATOR REMOVAL
Remove the following:
STAY NUT
– 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)
CLIP
Remove the bolt, bolt/washer, nut and trim clip (XL700VA)
(XL700VA only).
Remove the ECM stay.
BOLT BOLT/WASHER
Release the wire harness from the wire band and
harness clamp. WIRE BAND HARNESS CLAMP
Disconnect the alternator 3P (Natural) connector.
3P (NATURAL) CONNECTOR
Release the alternator wire from the wire guide.
WIRE GUIDE ALTERNATOR WIRE
Remove the reserve tank mounting bolt and move
the reserve tank slightly. BOLT
Alternator wire pass through the between reserve
tank and frame.
ALTERNATOR WIRE
11-4
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ALTERNATOR/STARTER CLUTCH
Loosen the bolts in Remove the bolts and left crankcase cover.
a crisscross pattern
BOLTS
in several steps.
• The left crankcase cover (stator) is magnetically
attracted to the flywheel, be careful during
removal.
• Be careful not to damage the alternator cover
mating surface.
• Engine oil will run out when the alternator cover
is removed. Set a oil pan under the engine and
add the recommended oil to the specified level
after installation.
LEFT CRANKCASE COVER
Be careful not to Remove the dowel pins and clean off the sealant
damage the mating from the mating surface. DOWEL PINS
surface.
Remove the bolt and stator wire holder from the left
crankcase cover. BOLT GROMMET
Remove the wire grommet.
HOLDER
Remove the bolts and stator from the left crankcase
cover. STATOR
BOLTS
11-5
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ALTERNATOR/STARTER CLUTCH
FLYWHEEL/STARTER CLUTCH
FLYWHEEL REMOVAL
For alternator Remove the left crankcase cover (page 11-4).
charging coil
IDLE GEAR REDUCTION GEAR
Remove the starter reduction gear and shaft.
inspection (page
Remove the starter idle gear and shaft.
17-9).
SHAFTS
The flywheel bolt Remove the flywheel bolt and washer while holding
has left hand the flywheel using the special tool. FLYWHEEL HOLDER
thread.
TOOL:
Flywheel holder 07725-0040001 or
equivalent commer-
cially available
BOLT/WAHSER
Remove the flywheel using the special tool.
FLYWHEEL
TOOL:
Rotor puller 07733-0020001
ROTOR PULLER
Remove the washer and needle bearing and woo-
druff key from the crankshaft. WOODRUFF KEY WASHER
• When woodruff key removal, be careful not to
damage the key groove and crankshaft.
• Do not lose the woodruff key.
NEEDLE BEARING
11-6
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ALTERNATOR/STARTER CLUTCH
STARTER IDLE/REDUCTION GEAR
INSPECTION
STARTER IDLE GEAR/SHAFT
Check the starter idle gear and shaft for wear or
damage. IDLE GEAR
SHAFT
STARTER REDUCTION GEAR/SHAFT
Check the starter reduction gear and shaft for wear
or damage. REDUCTION GEAR
SHAFT
STARTER DRIVEN GEAR/STARTER
CLUTCH REMOVAL
Check the operation of the one-way clutch by turn-
ing the starter driven gear. DRIVEN GEAR
You should be able to turn the driven gear counter-
clockwise smoothly, but the gear should not turn
clockwise.
Remove the starter driven gear from the flywheel
while turning the driven gear counterclockwise.
FLYWHEEL
11-7
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ALTERNATOR/STARTER CLUTCH
Remove the torx bolts while holding the flywheel
using the special tool. TORX BOLTS
TOOL:
Flywheel holder 07725-0040001 or
equivalent commer-
cially available
Remove the clutch outer and one-way clutch from
the flywheel. FLYWHEEL CLUTCH OUTER
ONE-WAY CLUTCH
STARTER CLUTCH INSPECTION
NEEDLE BEARING
Check the needle bearing for abnormal wear or
damage. NEEDLE BEARING
ONE-WAY CLUTCH/CLUTCH OUTER
Check the one-way clutch sprag for abnormal wear,
damage or irregular movement. ONE-WAY CLUTCH
• Do not remove the one-way clutch from the
clutch outer, unless it is necessary to replace
with a new one.
• If the spring is removed from the one-way clutch
groove, replace the one-way clutch assembly
with a new one.
Check the clutch outer for wear or damage.
Measure the clutch outer I.D.
SERVICE LIMIT: 74.46 mm (2.931 in) CLUTCH OUTER
11-8
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ALTERNATOR/STARTER CLUTCH
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.
SERVICE LIMIT: 57.73 mm (2.273 in)
Measure the driven gear I.D.
SERVICE LIMIT: 37.10 mm (1.461 in)
STARTER DRIVEN GEAR/STARTER
CLUTCH INSTALLATION
CLUTCH OUTER
FLYWHEEL
DRIVEN GEAR
ONE-WAY CLUTCH
30 N·m (3.1 kgf·m, 22 lbf·ft)
Clean and apply engine oil to the one-way clutch
sliding surface. ONE-WAY CLUTCH
Install the one-way clutch into the clutch outer with
its flange side facing the flywheel.
CLUTCH OUTER
11-9
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ALTERNATOR/STARTER CLUTCH
Install the clutch outer and one-way clutch to the fly-
wheel. CLUTCH OUTER/ONE-WAY CLUTCH
FLYWHEEL
Hold the flywheel using the special tool.
TORX BOLTS
TOOL:
Flywheel holder 07725-0040001 or
equivalent commer-
cially available
Clean and apply a locking agent to the torx bolt
threads (page 1-18).
Install and tighten the torx bolts to the specified
torque.
TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)
Install the starter driven gear to the flywheel while
turning the driven gear counterclockwise. DRIVEN GEAR
Recheck the one-way clutch operation (page 11-7).
FLYWHEEL
FLYWHEEL INSTALLATION
Apply engine oil to the needle bearing and install it
to the crankshaft. WOODRUFF KEY WASHER
Install the washer to the crankshaft.
Wipe any oil off the mating surface of the crankshaft
with flywheel and woodruff key groove.
During woodruff Install the woodruff key to the key groove of the
key installation, be crankshaft.
careful not to
damage the key
groove or
crankshaft.
NEEDLE BEARING
11-10
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ALTERNATOR/STARTER CLUTCH
Wipe any oil off the mating surface of the flywheel
with crankshaft. FLYWHEEL Align
Install the flywheel to the crankshaft, aligning its key
groove with the woodruff key.
Hold the flywheel using the special tool.
FLYWHEEL HOLDER
TOOL:
Flywheel holder 07725-0040001 or
equivalent commer-
cially available
Apply engine oil to the flywheel bolt threads and
seating surface.
The flywheel bolt Install and tighten the flywheel bolt with the washer
has left hand to the specified torque.
thread.
TORQUE: 157 N·m (16.0 kgf·m, 116 lbf·ft)
BOLT/WAHSER
Apply engine oil to the starter reduction gear and
starter idle gear shafts outer surface. "OUT" MARK REDUCTION GEAR
Install the starter reduction gear, idle gear and
shafts to the left crankcase as an assembly.
Install the starter reduction gear with its "OUT" mark
facing out.
Install the stator and left crankcase cover (page 11-
12).
IDLE GEAR SHAFTS
11-11
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ALTERNATOR/STARTER CLUTCH
STATOR INSTALLATION
12 N·m (1.2 kgf·m, 9 lbf·ft)
12 N·m (1.2 kgf·m, 9 lbf·ft)
WIRE HOLDER
STATOR
LEFT CRANKCASE COVER
Install the stator to the left crankcase cover.
Clean and apply a locking agent to the bolt threads STATOR
(page 1-18).
Install and tighten the stator bolts to the specified
torque.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
BOLTS
Install the grommets into the groove in the left
crankcase cover. BOLT GROMMET
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.
TORQUE: 12 N·m (1.2 kgf·m, 9 lbf·ft)
HOLDER
11-12
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ALTERNATOR/STARTER CLUTCH
Clean off the sealant from the left crankcase cover
mating surface.
Do not use an Apply liquid sealant (Three Bond 1207B or equiva-
organic solvent lent) to the left crankcase cover mating surface.
when wiping off the
excessive sealant.
Install the dowel pins.
DOWEL PINS
The left crankcase Install the left crankcase cover.
cover (stator) is
BOLTS BOLT
Clean and apply locking agent to the bolt threads as
magnetically
shown.
attracted to the
flywheel, be careful Install and tighten the left crankcase cover bolts in a
during installation. crisscross pattern in several steps.
LEFT CRANKCASE COVER
Route the alternator wire between the reserve tank
and frame. BOLT
Install and tighten the reserve tank mounting bolt.
ALTERNATOR WIRE
11-13
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ALTERNATOR/STARTER CLUTCH
Install the alternator wire to the wire guide.
WIRE GUIDE ALTERNATOR WIRE
Connect the alternator 3P (Natural) connector.
WIRE BAND HARNESS CLAMP
Route the wire Install the alternator wire to the wire band and har-
harness properly ness clamp.
(page 1-21).
3P (NATURAL) CONNECTOR
Install the ECM stay and trim clip (XL700VA only).
Install and tighten the nut, bolt/washer and bolt STAY NUT
securely.
Install the following:
– Drive sprocket cover (page 7-13)
– Heat guard plate mounting bolt (page 2-23) CLIP
– ECM (page 5-77) (XL700VA)
– Under cowl (page 2-13)
– Left front side cowl (page 2-9)
Check the engine oil level (page 3-12).
BOLT BOLT/WASHER
11-14
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