X500 Cap 12 (Statore e Ruota Libera)

12. A.C.
GENERATOR/STARTER CLUTCH XCITING 500
12
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12
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A.C. GENERATOR/STARTER CLUTCH

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SCHEMATIC DRAWING ------------------------------------------------- 12-1

SERVICE INFORMATION------------------------------------------------ 12-2
TROUBLESHOOTING----------------------------------------------------- 12-2
ALTERANTOR STATOR-------------------------------------------------- 12-3
FLYWHEEL/STARTER CLUTCH --------------------------------------- 12-4
12-0
12. A.C. GENERATOR/STARTER CLUTCH XCITING 500
SCHEMATIC DRAWING
12-1
SERVICE INFORMATION
GENERAL INSTRUCTIONS
• All servicing operations and inspections in this section can be made with the engine installed.
• Drain the coolant before removing the right crankcase cover.
• Be careful not to drain the coolant when the engine temperature is high. (Perform this operation
when the engine is cold.)
• Drain the coolant into a clean container.
• Drain the engine oil into a clean container before removing the right crankcase cover.
• When the right crankcase cover is installed, fill with the recommended engine oil and coolant.
Then, bleed air from the water jacket.
• Refer to section 17 for alternator inspection, and to section 18 for ignition pulse generator
inspection.
SPECIFICATIONS Unit: mm (in)

Item Standard Service Limit
Starter driven gear I.D. 27.026 (1.081)～27.045 (1.0818) 27.1 (1.084)
Starter driven gear O.D. 45.66 (1.8264)～45.673 (1.8292) 45.6 (1.824)
SPECIAL TOOLS
Flywheel puller E054
Flywheel holder E021
TORQUE VALUES
Flywheel nut: 55 N•m (5.5 kgf•m, 40 lbf•ft)
TROUBLESHOOTING
Starter motor turns, but engine does not turn
• Faulty starter clutch
• Damaged starter reduction gear
12-2
Right Crankcase Cover

ALTERNATOR STATOR
REMOVAL
Remove the right center body cover (page 2-

5).
Remove the exhaust muffler (page 2-15).
Remove water pump (page 6-10).
Remove the fifteen bolts and right crankcase

cover, dowel pins and gasket.
Stator Bolts Grommet

Remove the two pulse coil mount bolts.
Remove the three stator mount bolts,
grommet and the stator from the right
crankcase cover.
INSTALLATION
Install the stator and tighten the stator mount
bolts to the specified torque.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
Apply sealant to the grommet seating surface Bolts Pulse Coil

and install it to the cover groove properly.
Install the pulse coil and tighten mount bolts

to the specified torque.

Dowel Pins Gasket
Clean the mating surfaces of the right
crankcase and cover.
Install the dowel pins and gasket.

Install the right crankcase cover and tighten
the bolts in a crisscross pattern in 2 or 3 steps.
12-3
Flywheel Holder Nut/Washer

FLYWHEEL/STARTER CLUTCH
REMOVAL
Remove the right crankcase cover (page 12-
3).
Hold the flywheel with the special tool and

loosen the flywheel nut.
Special tool:
Remove the flywheel nut and washer.
Flywheel Puller
Remove the flywheel/starter driven gear
assembly using the special tool.
Special tool:
Flywheel puller E054
Remove the woodruff key.
Woodruff Key
12-4
Reduction Gear
Remove the reduction gear.
Driven gear
INSPECTION
Check the operation of the sprag clutch by
turning the driven gear.
You should be able to turn the driven gear
clockwise smoothly, but the gear should not
turn counterclockwise.
Remove the starter driven gear by turning the

driven gear.
Flywheel
Check the starter driven gear teeth for wear or

damage.
Measure the starter driven gear boss O.D..
Service limit: 45.6 mm (1.824 in)
Measure the starter driven gear bushing I.D..
Service limit: 27.1 mm (1.084 in)
12-5
Reduction Gear
Check the starter reduction gear teeth and
shaft for wear or damage.
Reduction Gear
Apply oil to the starter reduction gear.
Install the starter reduction gear to the right
crankcase.
Driven gear
Apply molybdenum oil solution to the

starter driven gear bushing.
Install the starter driven gear by turning the
driven gear clockwise.
Flywheel
12-6
Clean any oil from tapered portion of the

crankshaft.
Install the woodruff key in the crankshaft

key groove.
Woodruff Key
Clean any oil from the tappered portion of Flywheel Holder Nut/Washer
the flywheel I.D..
Install the flywheel/driven gear onto the

crankshaft, aligning the key way with
woodruff key.
Apply oil to the washer and flywheel nut

threads and seating surface.
Install the washer and flywheel nut to the
crankshaft.
Hold the flywheel with the special tool and

tighten the flywheel nut to the specified
torque.
Special tool:
12-7

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12. A.C.

GENERATOR/STARTER CLUTCH XCITING 500

A.C. GENERATOR/STARTER CLUTCH

SCHEMATIC DRAWING ------------------------------------------------- 12-1

SPECIFICATIONS Unit: mm (in)

Right Crankcase Cover

Remove the right center body cover (page 2-

Remove the fifteen bolts and right crankcase

Stator Bolts Grommet

Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)

Apply sealant to the grommet seating surface Bolts Pulse Coil

Install the pulse coil and tighten mount bolts

Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)

Install the dowel pins and gasket.

Flywheel Holder Nut/Washer

Hold the flywheel with the special tool and

Remove the flywheel nut and washer.

Remove the woodruff key.

Remove the starter driven gear by turning the

Check the starter driven gear teeth for wear or

Measure the starter driven gear boss O.D..

Service limit: 45.6 mm (1.824 in)

Measure the starter driven gear bushing I.D..

Service limit: 27.1 mm (1.084 in)

Apply molybdenum oil solution to the

Clean any oil from tapered portion of the

Install the woodruff key in the crankshaft

Install the flywheel/driven gear onto the

Apply oil to the washer and flywheel nut

Hold the flywheel with the special tool and

Torque: 55 N•m (5.5 kgf•m, 40 lbf•ft)

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