Table of Contents
Advertisement
CLEANING, INSPECTION
AND REPAIR
CAUTION
Do not strike or drop alternator rotor or damage to mag-
net adhesive may 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.
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 7-27.
Feed stator wiring (4) with attached
grommet (3) 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 (1) on left crankcase half. Secure stator
using four new Torx screws (2). Tighten screws to
30-40 in-lbs (3.4-3.5 Nm).
4.
Route stator wiring (4) below starter to frame upright.
5.
Route stator wiring upward along side of frame upright.
Connect stator wiring connector [P17] to voltage regulator.
6.
Secure stator wiring, along with any other wires and
hoses routed in the same location, to frame using cable
straps.
7-30
www.PlanDeGraissage.org
3560
Pipe
section
Sprocket
Figure 7-28. Pressing Rotor onto Sprocket
7.
See
Figure 7-28.
Attach rotor to sprocket.
a.
Position rotor on sprocket. Align holes in sprocket
with holes in rotor.
b.
Apply a drop of LOCTITE THREADLOCKER 242
(blue) to threads of each mounting bolt. Insert
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 (10.2-12.4 Nm).
8.
Install clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See
DRIVE/CLUTCH
in Section 6.
9.
Install primary cover. See
WARNING
Always connect positive battery cable first. If the positive
cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion resulting in personal injury.
CAUTION
Hold battery cable when loosening battery terminal hard-
ware. Failure to hold cable may cause battery damage.
10. Connect battery cables, positive cable first.
11. Test charging system. See
page 7-23.
Rotor
PRIMARY
PRIMARY CHAIN
in Section 6.
CHARGING SYSTEM
on
Advertisement
Table of Contents
