Caution

If the rotor is difficult to remove, turn the puller shaft using a wrench while tapping [B] the head of the puller shaft with a hammer. Do not attempt to strike the grab bar or the alternator rotor itself. Striking the bar or the rotor can cause the bar to bend or the magnets to lose their magnetism.

ELECTRICAL SYSTEM 16-25

Charging System

• Remove the rollers [A], springs [B], and spring caps [C] from the starter clutch [D].

• Holding the rotor [A] steady, remove the Allen bolts [B] to separate the rotor and starter clutch [C].

Starter Clutch Sprocket Removal

• Remove:

Alternator cover (see Alternator Rotor/Starter Clutch Re­moval)

Alternator rotor with Starter Clutch (see Alternator Ro­tor/Starter Clutch Removal)

• Remove the woodruff key [A] and spacer [B].

• Remove the starter chain guide [C].

• Remove the starter clutch sprocket [D], starter motor sprocket [E] and starter chain [F] as a set.

• In case that the starter motor has been removed, do the following:

О Remove the starter motor sprocket. ORemove the alternator rotor with the starter clutch, starter clutch sprocket and starter chain as a set.

Starter Clutch Sprocket Installation

• Apply a thin coat of molybdenum disulfide grease to the frictional surface between the crankshaft and the starter clutch sprocket.

• If the starter motor has been removed, install it first.

• Install the starter clutch sprocket, starter motor sprocket and starter chain as a set.

• Install the alternator rotor with the starter clutch and alter­nator cover.

Torque -Alternator Rotor Bolt: 69 N-m (7.0 kgf-m, 51 ft-lb) Alternator Cover Bolt: 11 N-m (1.1 kgf-m, 95 in-lb)

16-26 ELECTRICAL SYSTEM

Charging System

Alternator Rotor/Starter Clutch Installation

• Apply a non-permanent locking agent to the threads of the starter clutch Allen bolts, and tighten them to the specified torque in assembling the starter clutch onto the alternator rotor.

Torque -Starter Clutch Allen Bolts: 34 N-m (3.5 kgf-m, 25 ft-lb)

OBe careful that the rollers do not drop out of the starter clutch during assembly.

• Using a high flash-point solvent, clean off any oil or dirt that may be on the crankshaft taper [A] and rotor tapered hole [B].

• Fit the woodruff key securely in the slot [C] in the crank­shaft before installing the rotor assembly on the crank­shaft.

• Tighten the rotor bolt while holding the rotor steady with the flywheel holder, and turn the rotor bolt counterclock­ wise to install it.

Torque -Alternator Rotor Bolt: 69 N-m (7.0 kgf-m, 51 ft-lb) Special Tool - Flywheel Holder: 57001-1410

• Apply silicone sealant to the area [A] where the mating surface ends of the crankcase touch the alternator cover gasket.

Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

• Apply silicone sealant around the circumference of the wiring grommets before setting it in the notch in the al­ ternator cover.

Sealant - Kawasaki Bond (Liquid Gasket): 92104-1063

• Check that knock pins [B] are in place on the crankcase.

• Tighten the alternator cover bolts.

Torque-Alternator Cover Bolts: 11 N-m (1.1 kgf-m, 95 in-lb)

• Install the other removed parts.

• Check the engine oil level, and add if necessary (see En­gine Oil Level Inspection in the Engine Lubrication Sys­tem chapter).

Alternator Stator Removal

NOTE

О To keep the loss of engine oil to a minimum, set the motorcycle vertically.

• Remove the alternator cover (see Alternator Rotor and Starter Clutch Removal).

ELECTRICAL SYSTEM 16-27 Charging System

• 

  Remove the screws [A] and the holding plate [B] for the stator wiring.

• Unscrew the Allen bolts [C] and remove the stator [D]. Remove the grommet for the crankshaft sensor lead.

Alternator Stator Installation

• Apply silicone sealant [A] around the circumference of the wiring grommets before setting them in the notch in the alternator cover.

Sealant - Kawasaki Bond (Liquid Gasket): 92104-1063

• Install the grommet for the stator wiring and crankshaft sensor lead in this order.