Honda XL700V Service Manual
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Honda XL700V Service Manual

Honda XL700V Service Manual

Alternator/starter clutch
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See also: Owner's Manual , Manual
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 ······················· 11-12
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11-1

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Summary of Contents for Honda XL700V

  • Page 1 11. ALTERNATOR/STARTER CLUTCH COMPONENT LOCATION ························ 11-2 STATOR REMOVAL ································· 11-4 SERVICE INFORMATION ························· 11-3 FLYWHEEL/STARTER CLUTCH ·············· 11-6 TROUBLESHOOTING ······························· 11-3 STATOR INSTALLATION ······················· 11-12 11-1...

  • Page 2: Component Location

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

  • Page 3: Service Information

    ALTERNATOR/STARTER CLUTCH SERVICE INFORMATION 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 17-9). • For starter motor service (page 19-6). SPECIFICATIONS Unit: mm (in) ITEM...

  • Page 4: Stator Removal

    ALTERNATOR/STARTER CLUTCH STATOR REMOVAL Remove the following: STAY – 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) CLIP Remove the bolt, bolt/washer, nut and trim clip (XL700VA) (XL700VA only).
  • Page 5 ALTERNATOR/STARTER CLUTCH Remove the bolts and left crankcase cover. Loosen the bolts in BOLTS a crisscross pattern in several steps. • 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.

  • Page 6: Flywheel Removal

    ALTERNATOR/STARTER CLUTCH FLYWHEEL/STARTER CLUTCH FLYWHEEL REMOVAL Remove the left crankcase cover (page 11-4). For alternator IDLE GEAR REDUCTION GEAR charging coil Remove the starter reduction gear and shaft. inspection (page Remove the starter idle gear and shaft. 17-9). SHAFTS Remove the flywheel bolt and washer while holding The flywheel bolt FLYWHEEL HOLDER the flywheel using the special tool.
  • Page 7 ALTERNATOR/STARTER CLUTCH STARTER IDLE/REDUCTION GEAR INSPECTION STARTER IDLE GEAR/SHAFT Check the starter idle gear and shaft for wear or IDLE GEAR damage. SHAFT STARTER REDUCTION GEAR/SHAFT Check the starter reduction gear and shaft for wear REDUCTION GEAR or damage. SHAFT STARTER DRIVEN GEAR/STARTER CLUTCH REMOVAL Check the operation of the one-way clutch by turn-...

  • Page 8: Starter Clutch Inspection

    ALTERNATOR/STARTER CLUTCH Remove the torx bolts while holding the flywheel TORX BOLTS using the special tool. TOOL: Flywheel holder 07725-0040001 or equivalent commer- cially available Remove the clutch outer and one-way clutch from FLYWHEEL CLUTCH OUTER the flywheel. ONE-WAY CLUTCH STARTER CLUTCH INSPECTION NEEDLE BEARING Check the needle bearing for abnormal wear or...
  • Page 9 ALTERNATOR/STARTER CLUTCH 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: 57.73 mm (2.273 in) Measure the driven gear I.D. SERVICE LIMIT: 37.10 mm (1.461 in) STARTER DRIVEN GEAR/STARTER CLUTCH INSTALLATION CLUTCH OUTER...

  • Page 10: Flywheel Installation

    ALTERNATOR/STARTER CLUTCH Install the clutch outer and one-way clutch to the fly- CLUTCH OUTER/ONE-WAY CLUTCH wheel. FLYWHEEL Hold the flywheel using the special tool. TORX BOLTS TOOL: Flywheel holder 07725-0040001 or equivalent commer- cially available Clean and apply a locking agent to the torx bolt threads (page 1-18).
  • Page 11 ALTERNATOR/STARTER CLUTCH Wipe any oil off the mating surface of the flywheel FLYWHEEL Align with crankshaft. Install the flywheel to the crankshaft, aligning its key groove with the woodruff key. Hold the flywheel using the special tool. FLYWHEEL HOLDER TOOL: Flywheel holder 07725-0040001 or equivalent commer-...

  • Page 12: Stator Installation

    ALTERNATOR/STARTER CLUTCH 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. STATOR Clean and apply a locking agent to the bolt threads (page 1-18).
  • Page 13 ALTERNATOR/STARTER CLUTCH Clean off the sealant from the left crankcase cover mating surface. Apply liquid sealant (Three Bond 1207B or equiva- Do not use an lent) to the left crankcase cover mating surface. organic solvent when wiping off the excessive sealant. Install the dowel pins.
  • Page 14 ALTERNATOR/STARTER CLUTCH Install the alternator wire to the wire guide. WIRE GUIDE ALTERNATOR WIRE Connect the alternator 3P (Natural) connector. WIRE BAND HARNESS CLAMP Install the alternator wire to the wire band and har- Route the wire ness clamp. harness properly (page 1-21).

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