Alternator - Buell X1 2002 Service Manual

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ALTERNATOR

REMOVAL/DISASSEMBLY
1 1
WARNING WARNING
To protect against accidental start-up of vehicle, discon-
nect the negative battery cable before proceeding. Inade-
quate safety precautions could result in death or serious
injury.
1 1
WARNING WARNING
Always disconnect the negative battery cable first. If the
positive battery cable should contact ground with the
negative cable installed, the resulting sparks may cause
a battery explosion which could result in death or seri-
ous injury.
1. Disconnect both battery cables, negative cable first.
2. Remove primary cover. See
3. Remove clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See
DRIVE/CLUTCH.
4. Remove/disassemble rotor and/or stator, as required.
Refer to the following procedures.
Rotor
1. See Figure 7-23. Remove the eight bolts which secure
alternator rotor to engine sprocket.
2. See Figure 7-23. Position blocking under rotor. Press
sprocket free of rotor.
NOTE
Resistance to sprocket/rotor disassembly is due in part to the
magnetic force of the permanent rotor magnets.
Stator
1. See Figure 7-24. Disconnect stator wiring (4) from volt-
age regulator wiring at connector (5) [46] near the oil
pump.
2. Remove cable straps holding stator wire to oil filter hose.
3. Withdraw stator wiring (4) from behind the gearcase
cover.
4. Remove and discard the four TORX screws (2) which
secure stator (1) to 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.
5. Remove stator wiring grommet (3) from left crankcase
half.
6. Withdraw stator wiring (4) from grommet hole in left
crankcase half. Remove stator (1).
2002 Buell X1: Electrical
6.2 PRIMARY CHAIN.
6.5 PRIMARY
3558
Blocking
Bolts
Sprocket
Figure 7-23. Removing Rotor From Sprocket
b0082x7x
2
1. Stator
2. TORX Screw (4)
3. Grommet
4. Stator Wiring
5. Connector [46]
Figure 7-24. Stator Assembly
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.
7.7
Rotor
1
5
3
4
7-21