11. ALTERNATOR/STARTER CLUTCH

Transcription

1 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

2 ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION 157 N m (16.0 kgf m, 116 lbf ft) 11-2

3 SERVICE INFORMATION GENERAL ALTERNATOR/STARTER CLUTCH 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 ( ) (1.461) O.D ( ) (2.273) Starter clutch outer I.D ( ) (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 or equivalent commercially available TROUBLESHOOTING Starter motor turns, but engine does not turn Faulty starter clutch Damaged reduction gear Damaged starter idle gear 11-3

4 STATOR REMOVAL Remove 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. STAY NUT CLIP (XL700VA) Release the wire harness from the wire band and harness clamp. Disconnect the alternator 3P (Natural) connector. BOLT WIRE BAND BOLT/WASHER HARNESS CLAMP Release the alternator wire from the wire guide. 3P (NATURAL) CONNECTOR Remove the reserve tank mounting bolt and move the reserve tank slightly. Alternator wire pass through the between reserve tank and frame. WIRE GUIDE BOLT ALTERNATOR WIRE ALTERNATOR WIRE 11-4

5 Loosen the bolts in a crisscross pattern in several steps. Remove the bolts and left crankcase cover. 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. ALTERNATOR/STARTER CLUTCH BOLTS Be careful not to damage the mating surface. Remove the dowel pins and clean off the sealant from the mating surface. LEFT CRANKCASE COVER DOWEL PINS Remove the bolt and stator wire holder from the left crankcase cover. Remove the wire grommet. BOLT GROMMET Remove the bolts and stator from the left crankcase cover. STATOR HOLDER BOLTS 11-5

6 FLYWHEEL/STARTER CLUTCH For alternator charging coil inspection (page 17-9). FLYWHEEL REMOVAL Remove the left crankcase cover (page 11-4). Remove the starter reduction gear and shaft. Remove the starter idle gear and shaft. IDLE GEAR REDUCTION GEAR SHAFTS The flywheel bolt has left hand thread. Remove the flywheel bolt and washer while holding the flywheel using the special tool. TOOL: Flywheel holder or equivalent commercially available FLYWHEEL HOLDER Remove the flywheel using the special tool. TOOL: Rotor puller BOLT/WAHSER FLYWHEEL Remove the washer and needle bearing and woodruff key from the crankshaft. WOODRUFF KEY ROTOR PULLER 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

7 STARTER IDLE/REDUCTION GEAR INSPECTION STARTER IDLE GEAR/SHAFT Check the starter idle gear and shaft for wear or damage. ALTERNATOR/STARTER CLUTCH IDLE GEAR SHAFT STARTER REDUCTION GEAR/SHAFT Check the starter reduction gear and shaft for wear or damage. REDUCTION GEAR STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL Check the operation of the one-way clutch by turning the starter driven gear. You should be able to turn the driven gear counterclockwise smoothly, but the gear should not turn clockwise. Remove the starter driven gear from the flywheel while turning the driven gear counterclockwise. DRIVEN GEAR SHAFT FLYWHEEL 11-7

8 Remove the torx bolts while holding the flywheel using the special tool. TORX BOLTS TOOL: Flywheel holder or equivalent commercially available Remove the clutch outer and one-way clutch from the flywheel. FLYWHEEL CLUTCH OUTER STARTER CLUTCH INSPECTION NEEDLE BEARING Check the needle bearing for abnormal wear or damage. NEEDLE BEARING ONE-WAY CLUTCH 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: mm (2.931 in) CLUTCH OUTER 11-8

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. SERVICE LIMIT: mm (2.273 in) Measure the driven gear I.D. SERVICE LIMIT: 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. Install the one-way clutch into the clutch outer with its flange side facing the flywheel. ONE-WAY CLUTCH CLUTCH OUTER 11-9

10 Install the clutch outer and one-way clutch to the flywheel. CLUTCH OUTER/ONE-WAY CLUTCH FLYWHEEL Hold the flywheel using the special tool. TOOL: Flywheel holder 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) or equivalent commercially available TORX BOLTS Install the starter driven gear to the flywheel while turning the driven gear counterclockwise. Recheck the one-way clutch operation (page 11-7). DRIVEN GEAR During woodruff key installation, be careful not to damage the key groove or crankshaft. FLYWHEEL INSTALLATION Apply engine oil to the needle bearing and install it to the crankshaft. Install the washer to the crankshaft. Wipe any oil off the mating surface of the crankshaft with flywheel and woodruff key groove. Install the woodruff key to the key groove of the crankshaft. WOODRUFF KEY FLYWHEEL WASHER NEEDLE BEARING 11-10

11 Wipe any oil off the mating surface of the flywheel with crankshaft. Install the flywheel to the crankshaft, aligning its key groove with the woodruff key. FLYWHEEL Align The flywheel bolt has left hand thread. Hold the flywheel using the special tool. TOOL: Flywheel holder Apply engine oil to the flywheel bolt threads and seating surface. Install and tighten the flywheel bolt with the washer to the specified torque. TORQUE: 157 N m (16.0 kgf m, 116 lbf ft) or equivalent commercially available FLYWHEEL HOLDER Apply engine oil to the starter reduction gear and starter idle gear shafts outer surface. Install the starter reduction gear, idle gear and shafts to the left crankcase as an assembly. "OUT" MARK BOLT/WAHSER REDUCTION GEAR 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

12 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 (page 1-18). Install and tighten the stator bolts to the specified torque. STATOR TORQUE: 12 N m (1.2 kgf m, 9 lbf ft) Install the grommets into the groove in the left crankcase 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. TORQUE: 12 N m (1.2 kgf m, 9 lbf ft) BOLT BOLTS GROMMET HOLDER 11-12

13 Do not use an organic solvent when wiping off the excessive sealant. Clean off the sealant from the left crankcase cover mating surface. Apply liquid sealant (Three Bond 1207B or equivalent) to the left crankcase cover mating surface. Install the dowel pins. 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 as shown. Install and tighten the left crankcase cover bolts in a crisscross pattern in several steps. BOLTS BOLT 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

14 Install the alternator wire to the wire guide. WIRE GUIDE ALTERNATOR WIRE Route the wire harness properly (page 1-21). Connect the alternator 3P (Natural) connector. Install the alternator wire to the wire band and harness clamp. WIRE BAND HARNESS CLAMP 3P (NATURAL) CONNECTOR Install the ECM stay and trim clip (XL700VA only). Install and tighten the nut, bolt/washer and bolt securely. STAY NUT 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) CLIP (XL700VA) Check the engine oil level (page 3-12). BOLT BOLT/WASHER 11-14