Alternator Replacement

Disconnect and remove the battery hold-down strap from the battery box. Remove the battery from the motorcycle.

Figure 528 — Battery removal Clean the battery terminals using a wire brush to remove any oxidations. Use the same procedure to clean any oxidation from the cable ends. Clean the exterior of the battery, especially the top and terminals, with a solution of baking soda and water to remove any sulfation and accumulated dirt. Rinse thoroughly with water. Inspect the battery box and the cushion inside at the bottom. Clean and/or replace as necessary. Place the battery back in the box and install the holddown strap. Apply a coat of dielectric grease to the positive and negative battery terminals to help prevent corrosion. Insert the screw through the positive cable end. Thread the screw into the battery positive terminal and tighten to specification. Insert the screw through the negative cable end and thread it into the battery negative terminal. Tighten the screw to specification. Install the seat following the procedure in the FRAME AND ACCESSORIES SERVICE section.

Battery Replacement

The battery and/or cables can be replaced, if necessary, at the time of cleaning and inspection following the above procedure. Remember to always disconnect the ground cable first at the battery terminal when replacing either the positive or the negative cable, or the battery.

Alternator Replacement

Tools required:

5/32" hex bit

3/16" hex bit

5/16" hex bit

9/16" socket

3/4" wrench and/or socket

1-1/2" socket

Torque wrench Motorcycle lift

Rotor/Stator Removal

Disconnect the battery ground cable from the negative battery terminal to prevent an accidental engine start. Refer to the procedure under Battery and Cables in this section.

Raise the motorcycle off the ground to a suitable working height, using a motorcycle lift. Disconnect the shift rod from the transmission lever, using a 3/16” hex bit.

Figure 529 — Transmission shift rod Place a drain pan under the drain plug at the bottom of the primary chain housing. Remove the plug, using a 3/4” wrench, and allow the oil to drain from the housing. When completely drained, replace the plug and tighten to specification.

Remove the 15 screws at the perimeter of the outer primary housing, using a 3/16” hex bit. Remove the outer housing half. Remove the gasket from the housing and discard it.

Figure 530 — Outer primary housing removal Loosen the chain tensioner and remove the tensioner locknut, using a 9/16” socket, and slide the tensioner down to provide maximum slack in the chain.

Figure 531 — Loosening the chain tensioner Using a 1-1/2” socket, remove the compensator retaining nut and remove the assembly from the sprocket shaft.

Figure 532 — Compensator sprocket removal Remove the clutch assembly pressure plate and the clutch hub retaining nut. Slide the clutch hub assembly, primary drive chain, chain tensioner and engine sprocket off the engine crankshaft and the transmission input shaft. Refer to the PRIMARY DRIVE SERVICE section for procedures. Remove the starter motor drive pinion and starter motor. Refer to the STARTING SYSTEM SERVICE section for procedures. Remove the inner primary drive housing. Refer to the PRIMARY DRIVE SERVICE section for procedures. Remove the alternator rotor from the sprocket shaft. The rotor is held in place by the force of the integral magnets. Using a 5/32” hex bit, remove the four socket-head screws retaining the stator to the sprocket side of the crankcase.

Using a 3/32” hex bit, loosen the set screw retaining the connector in the engine crankcase. Push the stator connector through the crankcase flange and remove the stator.

Figure 533 — Stator electrical connector and lead position

Rotor/Stator Inspection

Clean any oil and accumulated dirt from the rotor and the stator. A mild solution of soap and water will work well for this purpose. Dry the parts thoroughly after cleaning. Metal particles will be drawn to the parts, particularly the rotor, because of the magnetism. Use a soft brush to remove these particles. When clean, inspect the rotor and stator for cracks and other damage. Look closely at the stator coil windings for damaged or chafed wires. Replace the rotor or coil if damaged.

Rotor/Stator Installation

Lubricate the stator connector and the crankcase bore. Insert the stator connector into its bore in the flange on the sprocket side of the crankcase and press the connector into position. Apply a thin coating of blue threadlock to the four socket-head screws.

Place the stator in position against the case and install the mounting screws. Using a 5/32” hex bit and torque wrench, tighten the screws to specification. Make sure the stator electrical leads are pressed against the crankcase. If not positioned properly, the leads can come in contact with the rotor and be damaged. Tighten the set screw, using a 3/32” hex bit, to secure the connector in place. Install the inner primary drive housing, the starter motor and drive pinion and the primary drive chain, sprockets and tensioner. Refer to the PRIMARY DRIVE SERVICE section and the STARTING SYSTEM SERVICE section for procedures. Place the compensator sprocket assembly in position on the engine crankshaft and seat the primary chain on the sprocket. Then, install the compensator retaining nut and tighten to specification, using a 1-1/2” socket and torque wrench. Adjust the primary chain as follows: • Move the adjuster up to the top notch and check for slack by pressing down on the chain in the top span. • If the chain cannot be depressed to the specified 5/16” slack, move the adjuster down to a position where the specified slack is reached. Tighten the adjuster to specification.

Figure 534 — Positioning the chain adjuster Install a new gasket and install the outer primary housing and retaining screws, using a 3/16” hex bit. Tighten the screws to specification. Apply blue threadlock to the shift rod screw. Connect the shift rod at the transmission, using a 3/16” hex bit. Tighten the screw to specification. Lower the motorcycle to the ground. Lower the kickstand and remove the motorcycle lift. Connect the battery ground cable to the negative battery terminal. Start the engine and check for proper operation of the charging system.