Buell 2002 P3 Service Manual page 368

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CLEANING AND INSPECTION
CAUTION
Do not strike or drop alternator rotor or damage to mag-
net adhesive could occur. Magnet adhesive damage can
result in rotor failure.
1. Clean rotor with a petroleum-base solvent. Remove all
foreign material from rotor magnets. Replace rotor if
rotor magnets are cracked or loose.
2. Clean stator by wiping with a clean cloth.
3. Examine stator leads for cracked or damaged insulation.
NOTE
The rotor and stator can be replaced individually if either is
damaged.
ASSEMBLY/INSTALLATION
Depending on whether the rotor, the stator, or both the rotor
and stator were removed/disassembled, perform the applica-
ble procedures which follow:
1. See Figure 7-54. Feed stator wiring with attached grom-
met into open grommet hole in left crankcase half.
2. Apply a light coating of clean engine oil or chaincase
lubricant to grommet. Install grommet into hole in left
crankcase half.
CAUTION
Stator TORX screws contain a thread locking compound.
Do not reuse existing screws. Always use new screws
with the proper thread locking compound. Loss of torque
on TORX fasteners could result in alternator damage.
3. Position stator on left crankcase half. Secure stator using
four new TORX screws. Tighten screws to 30-40 in-lbs
(3-5 Nm).
4. Route stator wiring under starter, behind footpeg support
bracket and under seat. Cable tie connector [46] halves
together.
NOTE
Temporarily attach a thin flexible "feed" or mechanic's wire to
the connector end of the stator wiring to assist in the routing
of the wiring.
7806
Pipe
Section
Sprocket
Figure 7-55. Pressing Rotor onto Sprocket
5. Connect alternator stator wiring to voltage regulator con-
nector [46] located behind left footrest support.
6. See Figure 7-55. Attach rotor to sprocket.
a. Position rotor on sprocket. Align holes in sprocket
with holes in rotor.
b. Apply a drop of LOCTITE THREADLOCKER 243
(blue) to threads of each mounting bolt. Insert the
eight mounting bolts through rotor and start bolts
into tapped holes in sprocket.
c. Position a section of pipe with an inside diameter
larger than the sprocket mounting hub over center of
rotor. Press rotor onto sprocket. Tighten bolts to 90-
110 in-lbs (10-12 Nm).
7. Install clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See
DRIVE/CLUTCH.
8. Install primary cover. See
9. Connect negative battery cable to battery terminal.
Tighten fastener to 60-96 in-lbs (7-11 Nm).
10. Test charging system. See
2002 Buell P3: Electrical
Rotor
6.6 PRIMARY
6.2 PRIMARY CHAIN.
7.13 CHARGING SYSTEM.
7-41