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StatoreRuotaLiberaX500 250 cap 12 .pdf



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12. A.C. GENERATOR/STARTER CLUTCH

XCITING 500/250

12
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12

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__________________________________________________________________________________

A.C. GENERATOR/STARTER CLUTCH
__________________________________________________________________________________

SCHEMATIC DRAWING ------------------------------------------------- 12-1
SERVICE INFORMATION------------------------------------------------ 12-2
TROUBLESHOOTING----------------------------------------------------- 12-2
ALTERANTOR STATOR-------------------------------------------------- 12-3
FLYWHEEL/STARTER CLUTCH --------------------------------------- 12-5

12-0

12. A.C. GENERATOR/STARTER CLUTCH
SCHEMATIC DRAWING

12-1

XCITING 500/250

12. A.C. GENERATOR/STARTER CLUTCH

XCITING 500/250

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 (XCITING 500)
Item
Starter driven gear I.D.
Starter driven gear O.D.

Standard
27.026 (1.081)~27.045 (1.0818)
45.66 (1.8264)~45.673 (1.8292)

SPECIFICATIONS (XCITING 250)
Item
Starter driven gear I.D.
Starter driven gear O.D.

Standard
22.026 (0.88104)~22.045 (0.8818)
42.195 (1.6878)~42.208 (1.68832)

Unit: mm (in)
Service Limit
27.1 (1.084)
45.6 (1.824)
Unit: mm (in)
Service Limit
22.1 (0.884)
41.5 (1.66)

SPECIAL TOOLS (XCITING 500)
Flywheel puller
E054
Flywheel holder
E021
SPECIAL TOOLS (XCITING 250)
Flywheel puller
E003
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

12. A.C. GENERATOR/STARTER CLUTCH

XCITING 500/250
Right Crankcase Cover

ALTERNATOR STATOR
REMOVAL (XCITING 500)
Remove the right center body cover (page 25).
Remove the exhaust muffler (page 2-16).
Remove water pump (page 6-15).
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
and install it to the cover groove properly.

Bolts

Pulse Coil

Install the pulse coil and tighten mount bolts
to the specified torque.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)
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

Dowel Pins

Gasket

12. A.C. GENERATOR/STARTER CLUTCH

XCITING 500/250

Bolts

ALTERNATOR STATOR

Water Inlet Hose

REMOVAL (XCITING 250)
Remove the right center body cover (page 25).
Remove the exhaust muffler (page 2-16).
Disconnect the water hoses from the right
crankcase cover.
Remove the nine bolts attaching the right
crankcase cover and the cover.
Water Outlet Hose

Remove the two pulse coil mount screws.
Remove the three stator mount bolts,
grommet and the stator from the right
crankcase cover.

A.C. Generator Stator

Bolts

Screws

Pulser Coil

Dowel Pins

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
and install it to the cover groove properly.
Install the pulse coil and tighten mount bolts
to the specified torque.
Torque: 12 N•m (1.2 kgf•m, 9 lbf•ft)

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.

12-4

12. A.C. GENERATOR/STARTER CLUTCH
Flywheel Holder

FLYWHEEL/STARTER CLUTCH
REMOVAL
Remove the right crankcase cover (page 123).
Hold the flywheel with the special tool and
loosen the flywheel nut.
Special tool:
Flywheel holder

E021

Remove the flywheel nut and washer.

Flywheel Puller

Remove the flywheel/starter driven gear
assembly using the special tool.
Special tool:
XCITING 500: Flywheel puller
XCITING 250: Flywheel puller

E054
E003

Remove the woodruff key.

Woodruff Key

12-5

XCITING 500/250
Nut/Washer

12. A.C. GENERATOR/STARTER CLUTCH

XCITING 500/250

Reduction Gear

Remove the reduction gear (XCITING 500).

Remove the reduction gear and shaft
(XCITING 250).

Starter Idle Gear

Reduction Gear

Check the starter reduction gear teeth and
shaft for wear or damage (XCITING 500).

12-6

12. A.C. GENERATOR/STARTER CLUTCH
Inspect the reduction gear and shaft for wear
or damage (XCITING 250).

XCITING 500/250

Reduction Gear

Shaft

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:
XCITING 500: 45.6 mm (1.824 in)
XCITING 250: 41.5.6 mm (1.66 in)

Measure the starter driven gear bushing I.D..
Service limit:
XCITING 500: 27.1 mm (1.084 in)
XCITING 250: 22.1 mm (0.884 in)

12-7

12. A.C. GENERATOR/STARTER CLUTCH

XCITING 500/250
Reduction Gear

Apply oil to the starter reduction gear.
Install the starter reduction gear to the right
crankcase.

Reduction Gear Shaft

Apply oil to the starter reduction gear and
shaft (XCITING 250).
Install the starter reduction gear and shaft
(XCITING 250) to the right crankcase.

Reduction Gear

Driven gear

Apply molybdenum oil solution to the
starter driven gear bushing.
Install the starter driven gear by turning the
driven gear clockwise.

Flywheel

12-8

12. A.C. GENERATOR/STARTER CLUTCH

XCITING 500/250

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
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:
Flywheel holder

E021

Torque: 55 N•m (5.5 kgf•m, 40 lbf•ft)

12-9

Flywheel Holder

Nut/Washer


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