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10. A.C. GENERATOR/STARTER CLUTCH
10-0
YUP 25 0
10
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A.C. GENERATOR/STARTER CLUTCH
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SCHEMATIC DRAWING ---------------------------------------------- 10-1
SERVICE INFORMATION -------------------------------------------- 10-2
TROUBLESHOOTING ------------------------------------------------- 10-2
RIGHT CRANKCASE COVER REMOVAL-------------------------- 10-3
STATOR REMOVAL --------------------------------------------------- 10-3
FLYWHEEL REMOVAL----------------------------------------------- 10-3
STARTER CLUTCH ---------------------------------------------------- 10-4
FLYWHEEL INSTALLATION---------------------------------------- 10-5
STATOR INSTALLATION -------------------------------------------- 10-6
RIGHT CRANKCASE COVER INSTALLATION------------------- 10-6
10
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10. A.C. GENERATOR/STARTER CLUTCH
10-1
YUP 25 0
SCHEMATIC DRAWING
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10. A.C. GENERATOR/STARTER CLUTCH
10-2
YUP 25 0
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 page 18-4 for A.C. generator inspection.
SPECIFICATIONS
Engine oil: SAE15W/40#
API-SG/CD
Oil capacity at change: 0.9 liter
Coolant: distilled water + coolant concentrate
Coolant capacity: 1165cc
SPECIAL TOOLS
Flywheel puller E003
Flywheel holder E021
SPECIFICATIONS
Item
Standard (mm)
Service Limit (mm)
Starter driven gear I.D.
22.026_ 22.045
22.15mm
Starter driven gear O.D.
42.195_ 42.208
41.5mm
TORQUE VALUES
Flywheel nut : 53.9_ 63.7N-m
TROUBLESHOOTING
Refer to page 1-21 for A.C. generator troubleshooting.
Starter motor rotates but engine does not start
• Faulty starter clutch
• Starter motor rotates reversely
• Weak battery
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10. A.C. GENERATOR/STARTER CLUTCH
10-3
YUP 25 0
RIGHT CRANKCASE COVER
REMOVAL
Disconnect the water hoses from the right
crankcase cover.
Remove the nine bolts attaching the right
crankcase cover and the cover.
STATOR REMOVAL
Remove the two pulser coil attaching screws
and the pulser coil.
Remove the three A.C. generator stator bolts
and the stator.
FLYWHEEL REMOVAL
Hold the flywheel with a flywheel holder and
remove the flywheel nut.
Flywheel holder E021
Remove the flywheel with a flywheel puller.
Flywheel puller E003
Water Outlet Hose
Bolts
Flywheel
Nut
Flywheel Holder
When removing the pulser coil and
stator, be careful not to damage them to
avoid shorted or broken wire.
＊
Water Inlet Hose
Screws
Bolts
Pulser Coil
A.C. Generator Stator
Flywheel Puller
Special
Special
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10. A.C. GENERATOR/STARTER CLUTCH
10-4
YUP 25 0
STARTER CLUTCH
REMOVAL
Remove the starter driven gear.
Remove the starter idle gear and shaft.
INSPECTION
Inspect the starter driven gear for wear or
damage.
Measure the starter driven gear I.D. and O.D.
Service Limits:
I.D. : 22.15mm replace if over
O.D. : 41.50mm replace if below
Inspect the starter idle gear and shaft for wear
or damage.
Starter Idle Gear
Shaft
Starter Driven Gear
Starter Idle Gear
Starter Driven Gear
Starter Idle Gear
Shaft
Page 6
10. A.C. GENERATOR/STARTER CLUTCH
10-5
YUP 25 0
Remove the starter one-way clutch rollers,
plungers and springs.
INSTALLATION
Install the starter driven gear onto the
crankshaft.
Install the starter idle gear and shaft.
FLYWHEEL INSTALLATION
Install the flywheel onto the crankshaft by
aligning the key on the crankshaft with the
groove in the flywheel.
Hold the flywheel with the flywheel holder
and tighten the flywheel nut.
Torque: 53.9_ 63.7N-m
Flywheel holder E021
Starter Idle Gear
Shaft
Groove
• Before installation, check and make
sure that the inside of the flywheel is
not contaminated.
＊
Starter Driven Gear
Flywheel
Key
Flywheel Holder
Special
Page 7
10. A.C. GENERATOR/STARTER CLUTCH
10-6
YUP 25 0
STATOR INSTALLATION
Install the A.C. generator stator on the right
crankcase cover and secure it with the three
bolts.
Install the pulser coil on the right crankcase
cover and secure it with the two screws.
Install the wire grommet in the groove in the
right crankcase cover securely.
RIGHT CRANKCASE COVER
INSTALLATION
Install the two dowel pins and a new gasket.
Install the right crankcase cover over the
crankcase, aligning the water pump shaft
groove with the oil pump shaft.
Tighten the nine right crankcase cover bolts.
Connect the water hoses to the right
crankcase cover.
Add the recommended engine oil. (!4-3)
Fill the cooling system with the specified
coolant. (!3-9)
Right Crankcase Cover
Oil Pump Shaft
Dowel Pins
Be sure to route the stator wire under the
pulser coil.
＊
Screws
Gasket
Pulser Coil
A.C. Generator Stator
Water Pump Shaft
• Be sure to bleed air from the water
jacket after filling the coolant.
＊
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