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Alternator Rotor Removal; Alternator Rotor Installation - Kawasaki KLX110 Service Manual

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Table of Contents
Charging System

Alternator Rotor Removal

Alternator Cover (see Alternator Cover Removal)
Starter Idle Gear and Washers
Wipe oil off the outer circumference of the rotor.
Hold the alternator rotor steady with the flywheel holder
[A], and remove the alternator rotor nut [B].
Special Tool - Flywheel Holder: 57001-1313
Remove the flywheel holder.
Using the flywheel puller [A] and rotor puller [B], remove
the alternator rotor from the crankshaft.
Special Tools - Flywheel Puller, M28 × 1.0: 57001-1471
Rotor Puller, M16/M18/M20/M22 × 1.5: 57001
-1216 or
Rotor Puller M18 × 1.5, M16 × 1.5: 57001
Hold the flywheel puller using a wrench, screw in the rotor
puller and remove the alternator rotor.
If the rotor is difficult to remove using a rotor puller
(57001-1216), tap the cap head on the rotor puller with
a hammer, while holding the rotor puller in the direction
of the turning.
Do not attempt to strike the grab bar or the alter-
nator rotor itself. Striking the bar or the rotor can
cause the bar to bend or the magnets to lose their

Alternator Rotor Installation

Apply molybdenum disulfide oil to the crankshaft [A].
Using high flash-point solvent, clean off any oil or dirt on
the crankshaft tapered portion [B] and rotor tapered por-
tion [C]. Dry them with a clean cloth.
Fit the woodruff key [D] securely in the slot on the crank-
Install the rotor [A] while turning the starter motor clutch
gear [B] clockwise.
Remove the starter idle gear and turn the torque limiter
gear [C] conterclockwise.


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