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Stator Removal; Stator Installation; Alternator Inspection - Kawasaki KLX110 Service Manual

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Charging System
Hold the rotor steady with the flywheel holder [A], tighten
the rotor nut [B].
Torque - Alternator Rotor Nut: 53.9 N·m (5.50 kgf·m, 39.8
Special Tool - Flywheel Holder: 57001-1313
Install the alternator cover (see Alternator Cover Installa-

Stator Removal

Alternator Cover (see Alternator Cover Removal)
Stator Screws [A]
Crankshaft Sensor Screws [B]
Alternator Lead Clamp Screws [C]
Lead Clamps [D]
Wiring Grommet [E]
Take off the stator and the crankshaft sensor as a set.

Stator Installation

Stator [A]
Crankshaft Sensor [B]
Clamps [C]
Run the alternator lead [D] as shown.
Torque - Stator Screws: 5.2 N·m (0.53 kgf·m, 46 in·lb)
Crankshaft Sensor Screws: 2.9 N·m (0.30 kgf·m,
26 in·lb)
Alternator Lead Clamp Screws: 5.2 N·m (0.53
kgf·m, 46 in·lb)
Using a high flash-point solvent, clean off any oil or dirt
that may be on the silicone sealant coating area. Dry
them with a clean cloth.
Apply liquid gasket around the circumference of the wiring
grommet [E].
Sealant - Liquid Gasket, TB1211F: 92104-0004
Set the stator wiring grommet securely in the notch of the
alternator cover.
Install the alternator cover (see Alternator Cover Installa-

Alternator Inspection

There are three types of alternator problems: short, open
(wire burned out), or loss in rotor magnetism.
A short or open in one of the coil wires will result in either
a low output, or no output at all.
A loss in rotor magnetism, which may be caused by drop-
ping or hitting the rotor by leaving it near an electromag-
netic field, or just by aging, will result in low output.


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