MAGNETO SYSTEM

GENERAL

  • Always perform the electric tests before removing or installing any components.
  • During assembly/installation, use the torque values and service products as in the exploded view.
  • Clean the threads before applying thread locker. Refer to SELF-LOCKING FASTENERS and LOCTITE APPLICATION at the beginning of this manual for the complete procedure.

Caution: Strictly adhere to torque wrench tightening specifications.Locking devices (e.g.: locking tabs, elastic stop nuts, self-locking fasteners, etc.) must be installed or replaced with new ones where specified. If the efficiency of a locking device is impaired, it must be replaced.Wear safety glasses and work in a well-ventilated area when working with strong chemical products. Also wear suitable non-absorbent gloves to protect your hands.

MAGNETO COVER

Magneto Cover Removal

  1. Lock crankshaft at TDC. (Refer to BOTTOM END).
  2. Drain engine oil. (Refer to LUBRICATION SYSTEM.)
  3. Disconnect crankshaft position sensor (CPS) connector and cut the tie rap.
  4. Remove magneto cover retaining screws.

    1 – magneto cover
    2 – retaining screws
    3 – crankshaft position sensor
  5. Pull magneto cover.

Magneto Cover Inspection and Cleaning

Check magneto cover for cracks or other damage. Replace if necessary.

NOTE: Clean all metal components with a nonferrous metal cleaner. Use Loctite Chisel (gasket remover), or a suitable equivalent.

Magneto Cover Installation

For installation, reverse the removal steps. Pay attention to the following:

  • Replace the magneto cover gasket.
  1. Apply Drei Bond sealing compound stator cable grommet as shown in following illustration.

    1 – Apply drei bond sealing compound.
  2. The tightening sequence for the screws on the magneto cover is indicated in the following illustration.

STATOR

STATOR Removal

  1. Remove magneto cover (Refer to MAGNETO COVER.)
  2. Remove screws securing the holding strip.
  3. Remove stator retaining screws, then the stator.

    1 – Stator
    2 – Stator retaining screws
    3 – Holding strip
    4 – Holding strip screws

Stator Inspection

  1. Check stator condition. Replace if damaged.
  2. Check if stator wires are brittle or otherwise damaged.
  3. For electrical inspection, refer to CHARGING SYSTEM.

Stator Installation

For installation, reverse the removal steps. However, pay attention to the following:

  • When installing the stator take care that the cable is in place (guide for wire).
  • NOTE: There is only one position for the stator (notch in the magneto housing cover).

    1 – Threads for cable holding strip
    2 – Notch for stator

ROTOR

Rotor Removal

  1. Lock crankshaft with crankshaft locking bolt. (Refer to BOTTOM END.)
  2. Remove magneto cover. (Refer to MAGNETO COVER.)
  3. Remove screw and washer securing rotor to crankshaft.

    1 – Screw M16
    2 – Washer
    3 -- Rotor
  1. Install magneto puller and crankshaft, then, remove rotor.

    MAGNETO PULLER

    CRANKSHAFT PROTECTOR
    NOTE: Use grease to placeprotector on the crankshaft end before screwing on the magneto puller.

    1 – Rotor
    2 – Magneto puller
  1. Screw magneto puller bolt to remove rotor.

Rotor Inspection

  1. Check inner side of rotor for scratches or other damage.
  2. Check keyway of the rotor for wear or damages.
  3. Check if trigger wheel teeth are bent or damaged.

    1 – Rotor with trigger wheel
  4. Check the woodruff and keyway on the crankshaft for wear or damages and replace parts if necessary.

Rotor Installation

For installation, reverse removal steps. However, pay attention to the following:

  • Clean the crankshaft taper and rotor with the pulley flange cleaner.
    CAUTION: Taper on crankshaft and rotor must be free of grease.Oil sprag clutch is inside the sprag clutch housing; install sprag clutch gear.

    1 – Sprag clutch
    2 – Sprag clutch housing
    3 – Sprag clutch gear
    4 – Apply engine oil here
  • Slide the rotor onto the crankshaft. The woodruff key and the keyway must be aligned.
  • Rotate the starter double gear counterclockwise to align the intermediate gear teeth with the sprag clutch gear.

    1 – Starter double gear
    2 – Sprag clutch gear
    3 – Intermediate gear

SPRAG CLUTCH

Sprag Clutch Removal

  1. Remove magneto cover. (Refer to MAGNETO COVER.)
  2. Loosen the sprag clutch housing screws located inside the rotor.
  3. Remove rotor. (Refer to ROTOR.)
  4. Remove sprag clutch gear.
  5. Remove sprag clutch housing screws and sprag clutch housing.

    1 – Sprag clutch housing screws
    2 – Rotor
    3 – Sprag clutch
    4 – Sprag clutch housing

Sprag Clutch Inspection

  1. Inspect sprag clutch and prag clutch housing for wear and damage. If sprag clutch, housing and/or gear are worn or damaged, allparts must be replaced at the same time.
  2. Check collar of sprag clutch gear, and replace if worn or damaged.
  3. Perform a functional test on the sprag clutch. To do so, rotate the sprag clutch gear in the sprag clutch.
    NOTE:Sprag clutch must lock in counterclockwise direction.

    SPRAG CLUTCH FUNCTIONAL TEST
    1 – Lock

Sprag Clutch Installation

For installation, reverse the removal procedure. Pay close attention to the following details.

1.Apply Loctite 648 (green) on the threads of the sprag clutch housing screws.

2.Install screw but do not torque yet.

3.Apply engine oil on sprag clutch and inside sprag clutch gear hole.

1 – Sprag clutch
2 – Sprag clutch housing

4.Install rotor then torque sprag clutch housing screws to 30 N/m.

SPRAG CLUTCH GEAR

Sprag Clutch Gear Removal

  1. Remove rotor. (See ROTOR.)
  2. Pull sprag clutch gear from rotor.

    1 – Rotor
    2 – Sprag clutch gear

Sprag Clutch Gear Inspection

  1. Inspect gear, especially teeth and sprag clutch collar, for wear and other damage.
  2. Check needle bearing condition. Replace sprag clutch gear if necessary.

    1 – Teeth
    2 – Collar
    3 – Needle bearing

Sprag Clutch Gear Installation

To install, reverse the installation procedure.

NOTE: Apply engine oil on needle bearing and collar of sprag clutch gear.

STARTER-DRIVEN GEARS

The starter-driven gears are located on the engine MAG side behind the magneto cover.


1 – Intermediate gear
2 – Starter double gear
3 – Starter gear
4 – Location pins

Gear Removal

  1. Remove magneto cover. (Refer to MAGNETO COVER.)
  2. Remove location pins, starter double gear, and intermediate gear.

Gear Inspection

Inspect gears and location pins for wear and damage, and replace if needed.

Gear Installation

The installation is reverse of the removal procedure. Pay attention to the following details:

  • Apply Loctite 767 (anti-seize lubricant) on the starter gear before installing the starter double gear.
  • Apply engine oil on the location pins.