Buell 2004 XB9S Service Manual page 550

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CLEANING AND INSPECTION
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.
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 7-34. 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 (2) on left crankcase half. Secure stator
using four new TORX screws (1). Tighten TORX screws
to 30-40 in-lbs (3-4 Nm).
4. Route stator wiring (4) behind rear cylinder and in front of
transmission breather hose. See
COVER WIRING for remaining wire routing information.
3560
1.
2.
3.
5. See
a.
b.
c.
6. Install clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See
7. Install primary cover. See
8. Connect negative battery cable.
9. Test charging system. See
7.26 SPROCKET
2
1
Sprocket
Pipe section
Rotor
Figure 7-35. Pressing Rotor onto Sprocket
Figure 7-35. Attach rotor to sprocket.
Position rotor (3) on sprocket (1). Align holes in
sprocket with holes in rotor.
Insert the new eight mounting fasteners through
rotor and start fasteners into tapped holes in
sprocket.
Position a section of pipe (2) with an inside diameter
larger than the sprocket mounting hub over center of
rotor. Press rotor onto sprocket. Tighten fasteners to
90-110 in-lbs (10-12 Nm).
6.2 PRIMARY
7.7 CHARGING SYSTEM.
2004 Buell Lightning: Electrical
3
6.4 CLUTCH.
COVER.
7-31