ALTERNATOR/STARTER CLUTCH 125 Nem (12.5 kgm, feb) 30 Nem (3.0 kgm, bb Pee 22 ft 12 Nem (1.2 kgm, 9 {tb9. ALTERNATOR/STARTER CLUTCH ‘SERVICE INFORMATION 91 STARTER CLUTCH 94 ‘TROUBLESHOOTING 9-1 FLYWHEELINSTALLATION 9.6 LEFT CRANKCASE COVER LEFT CRANKCASE COVER | REMOVAL 9-2 ASSEMBLY 97 | LEFT CRANKCASE COVER LEFT CRANKCASE COVER DISASSEMBLY 9-3. INSTALLATION a7 | FLYWHEEL REMOVAL 93 SERVICE INFORMATION GENERAL * This ccotion covore so-vicing of the atomnator and starter the frame, For alternator inspection and troubleshooting, refer to the seciton 16 and 17, SPECIFICATION [z ITEM clutch, These opotations can be accomplished with the engine in STANDARD SERVICE LIMIT 57.768 mm (2.2738 2.2743 in} 57.66 mm (2.270 in) Startor driven gear 0.0, TORQUE VALUES Starter clutch bolts 90 Nem [9.0 kg-m,22 feb} Apaly a locking ayent to the threads Flywneal bolt 125 Nem (1.2.6 kg-m, 90 ft-lb) Apply MoS? paste ipage 2-14} to the threacs Lett crankcase cover bolt 12 Nem |1.2 kg-m, 9 ft-lbh Starter gear cover 12 Nem (1.2 kg-m, 9 ft-lb) TOOLS Common Flywheel holder 077250940000 or equivalent commarcislly available in U.S.A, Rotor puler (07733 0920001 or 07933. 3290001 (U.S.A. enly) Torx bi (740) 07703—0910109 or equivalent commercially available in U.S.A, TROUBLESHOOTING Starter mowr tums, but engine does not crank: + Faulty starter clutch + Faulty starter idle gzars + Faulty etarcer criven gear Starter motor does not turn: + Faulty starter motor (section 18) + Faulty starting citcuit (section 18) + Bound idle gears 9-1ALTERNATOR/STARTER CLUTCH LEFT CRANKCASE COVER REMOVAL Remove the following: — five socket belts — sterter gear cover — cowel pins ~ gasket ~ shaft, reduction gaar and washers — chaft, idle goer and washers Check the idle gear anc reduction gear for excessive wear or damage. Remave the folowing: — gearshitt pedal crive sprocket cover [a seROCKET cove 4.) ee Disconnect the neutral ewitch wire fram the neutral switch, Flomove the belts and left crankcase cove NOTE + Loosen the bolts in a ciisscioss pattern in two or more steps.ALTERNATOR/STARTER CLUTCH Remove ihe folowing — dowel pins = gasket shaft, startor drive goar and wachers Check the sterter dnve gear for excessive wear or damage. LEFT CRANKCASE COVER DISASSEMBLY =) ures ARM Romove the followings: = Clutch lifter alece Clutch lifter arm = Spring Check the dust seal for damage or detericration, heck the nesdle bearing for wear ar damage. (4) NEEDLE BEARING, Remove the alternator wire holder and grommet. Fomove the three bolts and alternator startar. |4) HOLDER FLYWHEEL REMOVAL Remove the fiywheel boit while holding the flywheel with the ‘lywhee! holder. TooL: Flywheel holder 07725—0040000 (or equivalent commercially available in US.A,ALTERNATOR/STARTER CLUTCH Remove the flywheel using the ratar puller. TooL: Rotor puller 07733-0020001 or 07933—-3200001 (U.S.A, only) STARTER CLUTCH REMOVAL/DISASSEMBLY Fsmove the followings: — Ftywnee! {page 9-3} — Wesher and starter driven gear — Woodruf key Remove the needle bearing and washer, and check the needle beating for wear or damage. Install tha startor driven gear onte tho flywheel and inspect the starter clutch by turning the starter driven gear. The driven gear should 1m counter clockwise teely anc should not turn clockwise, if net so, replace the sterter clutch ‘Aiter inspection, remove the starter driven gear.ALTERNATOR/STARTER CLUTCH Loosen and remove the six torx bolts ina crisscross parttern in two or more steps, holding the fiywheel with the flywheel holder. (1) ToRX er ‘roots: Torx bit (140) 97703—0010100 or equivalent commercially available in U.S.A. Flywheel holder 077250040000 (or equivalent commercially avaliable in U.S.A. INSPECTION Ingpect the starter driven gear for excessive wear or damege. ‘Measure the 0.D. of the starter driven gear hub. [SERVICE LIMIT: 57.66 mm {2.270 int Ingpect the one way chitch for wear or damage and replace if necessary. ASSEMBLY/INSTALLATION (1) CLUTCH | (2) ONE WAY OUTER cLuTcH Install the one way clutch onto the clutch outer so that the flange side faces flywheel (3) FLANGE, SIDE 9-5 SRALTERNATOR/STARTER CLUTCH Apply locking egont t9 the threads of the torx batts 11) FLYWHEEL HOLDER Tighten the 1orx bolts in a crisscross partern in two or more Steps while hoiding the flywheel with the flywheel holder. TORQUE: 20 Nem (3.0 kg-m, 22 felb) TooLs: ‘Torx bit (T40) 077030010100 or equivalent commercially available in U.S.A, Flyvihee! holder 07725—0040000 or equivalent commercially available in U.S.A, (2) TORX BIT Install the starter driven gear onto the one way clutch, With the flywheel, install the starter clutch assy, onto the crankshaft, FLYWHEEL INSTALLATION Wips all oil of the crankshaft and from within the tapered hole in the flywheel. Install the folowing: — woadruff key — washer jedlo boating Install the flywheel onto the crankshaft, aligning the woodrutt key with the keywey, (2) NEEDLE BEARING Apply MoS2 pasta to the threads of the flywheel bolt Install the bolt and washer, and tighton tho belt while halding tha flywheel. TORQUE: 125 Nem (12.5 kg-m, 90 feb) TooL: Flywheel holder 07728—0040000 oF equivalent commercially available in U.S.A. os)LEFT CRANKCASE COVER ASSEMBLY ALTERNATOR STATOR INSTALLATION Install tha stator onto the left ovankease cover and apply @ locking agent to the threads of the stator mounting bolts, Tighten the three bolts. Route the stator wire and install the wire grommet into the ‘groova of the caver as shown, CLUTCH LIFTER ARM INSTALLATION Install the spring onto the lifter arm. Incort the lifter arm and heok the pring to the loft cranksase Turn the lifter arm and install the lifter piece, aligning the groove on the lifter arm with the bottom of the lifter piece. LEFT CRANKCASE COVER INSTALLATION Install the following: — washer and shaft — starter crive gear NOTE Install the starter drive gear with the “OUT mark facing Install the dowel pins and a new gaskot 7 WASHER ALTERNATOR/STARTER CLUTCH 1) STATOR MOUNTING: BOLT [2) HOLDER \ 43) GROMMET he G 3 (LIFTER ARM (3) LIFTER PIECE oO SSi2) serine far Drive 8. 13h*0U EAR Sagi CASKET PALTERNATOR/STARTER CLUTCH Install the left crankcase cover and connect the neutral switch Put the neutral switch wire into the groove of the left crank: Instell the left crankcase cover with & clamp, ard tighten the left crankcase cover bolts In a crisscross pactern In two oF more steps. TORQUE: 12 Nim (1.2 kg-mn, 9 ft Ib) Install the drive sprocket caver and secure it with three bolts. Install the gearshift pecal. aligning the punch marks on the podal and goarchift spindl Secure the pedal with a bolt Install the shaft and idle gear with the washers. Install tho shaft and reduction gear with the wachALTERNATORI/STARTER CLUTCH Install the dowel pins end & new gasket Install the starter gear cover and secure it with the five boits. TORQUE: 12 Nem (1.2 kg-m, 9 fb)