buell s1 lightning '97 Manual
7-30
CLEANING, INSPECTION
AND REPAIR
AND REPAIR
1
CAUTION
Do not strike or drop alternator rotor or damage to mag-
net adhesive may occur. Magnet adhesive damage can
result in rotor failure.
net adhesive may occur. Magnet adhesive damage can
result in rotor failure.
1.
Clean rotor with a petroleum-base solvent. Remove all
foreign material from rotor magnets. Replace rotor if rotor
magnets are cracked or loose.
foreign material from rotor magnets. Replace rotor if rotor
magnets are cracked or loose.
2.
Clean stator by wiping with a clean cloth.
3.
Examine stator leads for cracked or damaged insulation.
NOTE
The rotor and stator can be replaced individually if either is
damaged.
damaged.
ASSEMBLY/INSTALLATION
Depending on whether the rotor, the stator, or both the rotor
and stator were removed/disassembled, perform the applica-
ble procedures which follow:
and stator were removed/disassembled, perform the applica-
ble procedures which follow:
1.
See
Feed stator wiring (4) with attached
grommet (3) into open grommet hole in left crankcase
half.
half.
2.
Apply a light coating of clean engine oil or chaincase
lubricant to grommet. Install grommet into hole in left
crankcase half.
lubricant to grommet. Install grommet into hole in left
crankcase half.
1
CAUTION
Stator TORX screws contain a thread locking compound.
Do not reuse existing screws. Always use new screws
with the proper thread locking compound. Loss of torque
on TORX fasteners could result in alternator damage.
Do not reuse existing screws. Always use new screws
with the proper thread locking compound. Loss of torque
on TORX fasteners could result in alternator damage.
3.
Position stator (1) on left crankcase half. Secure stator
using four
using four
new
Torx screws (2). Tighten screws to
30-40
in-lbs
(3.4-3.5 Nm).
4.
Route stator wiring (4) below starter to frame upright.
NOTE
Temporarily attach a thin flexible “feed” or mechanic’s wire to
the connector end of the stator wiring to assist in the routing
of the wiring
the connector end of the stator wiring to assist in the routing
of the wiring
5.
Route stator wiring upward along side of frame upright.
Connect stator wiring connector [P17] to voltage regulator.
Connect stator wiring connector [P17] to voltage regulator.
6.
Secure stator wiring, along with any other wires and
hoses routed in the same location, to frame using cable
straps.
hoses routed in the same location, to frame using cable
straps.
7.
Attach rotor to sprocket.
a. Position rotor on sprocket. Align holes in sprocket
with holes in rotor.
b. Apply a drop of LOCTITE THREADLOCKER 242
(blue) to threads of each mounting bolt. Insert
mounting bolts through rotor and start bolts into
tapped holes in sprocket.
mounting bolts through rotor and start bolts into
tapped holes in sprocket.
c. Position a section of pipe with an inside diameter
larger than the sprocket mounting hub over center of
rotor. Press rotor onto sprocket. Tighten bolts to 90-
110
rotor. Press rotor onto sprocket. Tighten bolts to 90-
110
in-lbs
(10.2-12.4 Nm).
8.
Install clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See
sprocket/rotor assembly as a unit. See
PRIMARY
DRIVE/CLUTCH
in Section 6.
9.
Install primary cover. See
PRIMARY CHAIN
in Section 6.
1
WARNING
Always connect positive battery cable first. If the positive
cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion resulting in personal injury.
cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion resulting in personal injury.
1
CAUTION
Hold battery cable when loosening battery terminal hard-
ware. Failure to hold cable may cause battery damage.
ware. Failure to hold cable may cause battery damage.
10. Connect battery cables, positive cable first.
11. Test charging system. See
on
Figure 7-28. Pressing Rotor onto Sprocket
Sprocket
3560
Rotor
Pipe
section