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12. ALTERNATOR/STARTER CLUTCH

SERVICE INFORMATION······················ 12-2 STATOR/CKP SENSOR························ 12-5

TROUBLESHOOTING ·························· 12-2 FLYWHEEL ········································ 12-5

COMPONENT LOCATION ····················· 12-2 STARTER CLUTCH ····························· 12-8

LEFT CRANKCASE COVER·················· 12-3

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ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
ALTERNATOR/STARTER CLUTCH

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 20-7).
• For CKP sensor inspection (page 12-5).
• For starter motor service (page 6-6).
TOOLS
Flywheel holder Flywheel puller
07725-0040001 07733-0020001

or 07933-3950000 (U.S.A. only)

TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter reduction gear/shaft
• Damaged or faulty starter motor pinion gear
• Damaged starter driven gear

COMPONENT LOCATION
138 N·m (14.1 kgf·m, 102 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

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ALTERNATOR/STARTER CLUTCH
LEFT CRANKCASE COVER
REMOVAL/INSTALLATION

• Place a clean oil pan under the engine because

[2]
engine oil will flow out when removing the left
crankcase cover. Add the recommended engine oil
to the specified level after installation (page 3-10).
Support the motorcycle in an upright position on a level
surface.
Remove the following:
– side cover (page 2-4)
– gearshift pedal (page 11-15)
– drive sprocket cover (page 2-7)
– regulator/rectifier cover (page 20-7)
Disconnect following:
[1]
– CKP sensor 2P (Red) connector [1]
– alternator 3P (Gray) connector [2]
Remove the wire band [1] and CKP sensor wire [2] out
of the frame.

[1]

[2]

Loosen the air cleaner housing mounting bolts [1].

[2]
Remove the stator wire harness [2] out of the frame.
[1]

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ALTERNATOR/STARTER CLUTCH
Loosen the left crankcase cover socket bolts [1] in a
[1]
crisscross pattern in 2 or 3 steps.
Remove the following:
– socket bolts
– left crankcase cover [2]

• The left crankcase cover (stator) is magnetically

attracted to the flywheel, be careful during removal
and installation.

[2]

Remove the dowel pins [1].

Be careful not to Clean the crankcase and cover mating surfaces
damage the mating thoroughly. [1]
surfaces.
Installation is in the reverse order of removal.
TORQUE:
Left crankcase cover socket bolt:
12 N·m (1.2 kgf·m, 9 lbf·ft)

• Apply liquid sealant to the crankcase and crankcase

cover as shown (page 1-18).
Check the oil level (page 3-10).
Make sure there are no oil leaks.
Crank case side:

10 – 15 mm
(0.4 – 0.6 in)

10 – 15 mm
(0.4 – 0.6 in)

Crank case cover side:

Do not apply liquid

sealant to this area

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ALTERNATOR/STARTER CLUTCH
STATOR/CKP SENSOR
REMOVAL/INSTALLATION
Remove the left crankcase cover (page 12-3).
Remove and install the stator/CKP sensor as shown in the following illustration.
• Apply locking agent to the stator and CKP sensor bolt threads (page 1-18).
• Apply sealant to the alternator/CKP sensor wire grommet sealing surface (page 1-18).
Installation is in the reverse order of removal.

ALTERNATOR STATOR BOLT CKP SENSOR BOLT

10 N·m (1.0 kgf·m, 7 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft)

STATOR

LEFT CRANKCASE COVER

CKP SENSOR

FLYWHEEL
REMOVAL
Remove the left crankcase cover (page 12-3).
[2]
Remove the starter reduction gear shaft [1] and starter
reduction gear [2].

[1]

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ALTERNATOR/STARTER CLUTCH
Hold the flywheel [1] using the special tool and loosen
[1] [2]
the flywheel bolt [2].

• Set the holding block [3] of the flywheel holder [4]

avoiding the flywheel reluctors.
TOOL:
Flywheel holder 07725-0040001
Remove the flywheel bolt and washer [5].

[4] [3] [5]

Remove the flywheel [1] using the special tool.

[1]
TOOL:
[2] Flywheel puller 07733-0020001 or
07933-3950000
(U.S.A. only)

[2]

Be careful not to Remove the woodruff key [1].

[1]
damage the key
groove and
crankshaft.

INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation. Replace if necessary.
– starter reduction gear shaft
– starter reduction gear
– woodruff key
– needle bearing

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ALTERNATOR/STARTER CLUTCH
INSTALLATION
Be careful not to Install the woodruff key [1].
[2] [1]
damage the key
Apply engine oil to the needle bearing [2] rotating area.
groove and
crankshaft.

Clean any oil from the crankshaft tapered area and

[1]
flywheel thoroughly.
Install the flywheel [1] while aligning the woodruff key
on the crankshaft with flywheel keyway.
Align

Apply engine oil to the flywheel bolt threads and seating

[3] [2]
surface.
Install the washer [1] and flywheel bolt [2].
Hold the flywheel [3] using the special tool and tighten [4]
the flywheel bolt to the specified torque.

• Set the holding block [4] of the flywheel holder [5]

avoiding the flywheel reluctors.
TOOL:
Flywheel holder 07725-0040001

TORQUE: 138 N·m (14.1 kgf·m, 102 lbf·ft) [5] [1]

Apply molybdenum oil solution to the starter reduction

[1]
gear shaft outer surface.
Install the starter reduction gear [1] and shaft [2].
Install the left crankcase cover (page 12-3).

[2]

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ALTERNATOR/STARTER CLUTCH
STARTER CLUTCH
ONE-WAY CLUTCH OPERATION
INSPECTION
Remove the flywheel (page 12-5).
[1]
Check the operation of the one-way clutch by turning
the starter driven gear [1].
Make sure that the starter driven gear turns
counterclockwise smoothly and does not turn
clockwise.

REMOVAL
Remove the flywheel (page 12-5).
[1]
Remove the starter driven gear [1] while turning the
starter driven gear counterclockwise.

Hold the flywheel [1] using the special tool and remove
[1] [4]
the starter clutch socket bolts [2].

• Set the holding block [3] of the flywheel holder [4]

avoiding the flywheel reluctors. [3]
TOOL:
Flywheel holder 07725-0040001

[2]

Remove the starter clutch assembly.

[1]
Remove the starter one-way clutch [1] from the starter
clutch outer [2].

[2]

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ALTERNATOR/STARTER CLUTCH
INSPECTION
Inspect the following parts for scratch, damage,
abnormal wear and deformation. Replace if necessary.
– starter driven gear
– starter clutch outer
– starter one-way clutch
Measure each part according to ALTERNATOR/
STARTER CLUTCH SPECIFICATIONS (page 1-9).
Replace any part if it is out of service limit.

INSTALLATION

STARTER DRIVEN GEAR

STARTER CLUTCH OUTER

ONE-WAY CLUTCH

FLYWHEEL

29 N·m (3.0 kgf·m, 21 lbf·ft)

Apply engine oil to the starter one-way clutch contacting

[1]
surface.
Install the starter one-way clutch [1] into the starter
clutch outer [2].
Install the starter clutch assembly onto the flywheel [3].

[3] [2]

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ALTERNATOR/STARTER CLUTCH
Hold the flywheel [1] using the special tool.
[1] [3]

• Set the holding block [2] of the flywheel holder [3]

avoiding the flywheel reluctors.
[2]
TOOL:
Flywheel holder 07725-0040001
Apply locking agent to the starter clutch socket bolt
threads (page 1-18).
Install and tighten the starter clutch socket bolts [4] to
the specified torque.
TORQUE: 29 N·m (3.0 kgf·m, 21 lbf·ft) [4]

Install the starter driven gear [1] into the starter clutch
[1]
outer while turning the starter driven gear
counterclockwise.
Check the one-way clutch operation (page 12-8).
Install the flywheel (page 12-7).

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