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REMOVING THE ROTOR
1. Remove:
• Nut (rotor) "1"
• Washer
Use the sheave holder "2".
Sheave holder:
YS-1880-A/90890-
01701
2. Remove:
• Rotor "1"
Use the rotor puller "2".
Rotor puller:
YM-04142/90890-04142
REMOVING THE STARTER
CLUTCH
1. Remove:
• Starter clutch assembly cover "1"
Insert a thin screwdriver or the like
under the convexity "a" and remove
the starter clutch assembly cover by
prying it gently to void damage to the
cover.
2. Remove:
• Starter clutch "1"
Using a thin screwdriver or the like,
remove the plate "a" while prying it
upward little by little.
AC MAGNETO AND STARTER CLUTCH
CHECKING THE AC MAGNETO
1. Inspect:
• Rotor inner surface "a"
• Stator outer surface "b"
→
Damage
Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace AC magneto
and/or stator.
CHECKING THE WOODRUFF KEY
1. Inspect:
• Woodruff key "1"
→
Damage
Replace.
CHECKING THE STARTER
CLUTCH
1. Check:
• Starter clutch
→
Damage/wear
Replace.
2. Check:
• Idle gear
• Idle gear shaft
• Starter clutch drive gear
Pitting/burrs/chips/roughness/
→
wear
Replace the defective
parts.
3. Check:
• Starter clutch operation
a. Install the starter clutch drive gear
"1" onto the starter clutch "2" and
hold the starter clutch.
5-48
b. When turning the starter clutch
drive gear counterclockwise "B",
the starter clutch and the starter
clutch drive gear should engage.
If the starter clutch drive gear and
starter clutch do not engage, the
starter clutch is faulty and must be
replaced.
c. When turning the starter clutch
drive gear clockwise "A", it should
turn freely. If the starter clutch
drive gear does not turn freely, the
starter clutch is faulty and must be
replaced.
CHECKING THE TORQUE LIMITER
1. Check:
• Torque limiter
→
Damage/wear
Replace.
INSTALLING THE AC MAGNETO
AND STARTER CLUTCH
1. Install:
• Stator "1"
• Bolt (stator) "2"
Bolt (stator):
7 Nm (0.7 m•kg, 5.1
ft•lb)
• Pickup coil "3"
• Holder "4"
• Bolt (pickup coil) "5"
Bolt (pickup coil):
10 Nm (1.0 m•kg, 7.2
ft•lb)
• Pass the AC magneto lead "5" un-
der the pickup coil.
• Pass the AC magneto lead "4" un-
der the holder as shown.
• Take care not to catch the AC mag-
neto lead between crankcase cover
ribs.
• Tighten the bolt (stator) using the
T25 bit.
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