18.14 ServiceManual-RocketIll

Alternator

Removal

1. Removetherider'sseat.

2. Disconnectthebattery,negative(black)leadfirst.

3. Removetheengineasdescribedonpage10.2.

4. Releasetheboltssecuringthestartermotortothealternatorcover.

1. Startermotor

2. Startermotorfixings

3. Alternatorcover

5. Releasetheboltssecuringthealternatorcovertotherearoftheengine.

6. Withdraw the alternator cover from thecrankcase.

Note:

• TousetoolT3880201,insertthetoolpegsintoapairofrotorholes.However,toolT3880201willnotengagewitheverypairofholesintherotor.Theholesareoffsetandsothetoolwillonlyengagewithcertainpairsofholes.

Toremovetherotor,preventthecrankshaftfromrotatingusingtoolT3880201,andremovethecentreboltandwasherfromtheendofthecrankshaft.

1.Rotor

2.Rotorbolt

3.ToolT3880201

8. ScrewtoolT3880200intotherotorcentre.

9. PreventtherotorfromturningusingtoolT38B0201whiletighteningtoolT3880200.Thiswillreleasethetaperseatingoftherotortothecrankshaft.

2.ToolT3880200

3.ToolT3880201

8. Withdrawtherotorandtoolasanassemblyandthenseparatethetoolfromtherotor.

Note:

• Ifremovingthestator,makeanote ofthecableroutingbeforeremovingthecableretainer.

ServiceManual- RocketIll

18.15

8. Toremovethestator,releasethetwoboltssecuringthecableretainertothecrankcase.

1. Cableretainer

2. Bolts

12.Releasethethreeboltssecuringthestatortothecrankcase.

1. Stator

2. Statorbolts

13.Withdrawthestatorfromthecrankcase.

Inspection

1. Inspectthekeyinthecrankshaft for damageanddistortion.Replacethekeyifnecessary.

2. Inspecttherotorfordamageandhighspotstothetaper centre.Replacetherotorifnecessary.

3. Inspectthestatorforsignsofoverheatingandshort/opencircuits.Replaceasnecessary.

Assembly

1. Locatethestatortothecrankcase.

2. Applysiliconesealertothecablegrommetandalignthecabletothecrankcaseexitslot.

3. Fitthecableretainerbracket,routingthecablesasnotedonstripdown.Tightentheretainerbolts to12Nm.

1.Stator

2. Cableretainerbracket

3. Fixings

4. Tightenthestatorboltsto12Nm.

5. Assembletherotortothekeywayonthecrankshaft.

6. Fittheboltandwashertothethreadedholeinthecrankshaft.

7. RefittoolT3880201topreventthecrankshaftfromrotating.

8. Tighten therotor boltto120Nm.

1. Rotor

2. Rotorbolt

3.ToolT3880201

18.16 ServiceManual-RocketIll

9. RemovetoolT3880201.

10. Incorporatinganewgasket,refitthealternatorcover totherearoftheengine.

11. Tightenthealternatorcoverboltsto9Nm.

12. Incorporatinganew0-ringseal,fitthestartermotorandtightenthe starterfixingsto27Nm.

13. Refittheengineasdescribedonpage10.5.

14. Reconnectthebatterypositive(red)leadfirst.

15. Refittherider'sseat.

AlternatorRectifier

Note:

• Thealternatorrectifierisattachedtothebatterybox.Therectifierdoesnotcontainanyserviceablepartsandmustbereplacediffaulty.

Removal

1. Removetherider'sseatasdescribedonpage

17.9.

2. Disconnectthebattery,negative(black)leadfirst.

3. Removetheleft handsidecover asdescribedonpage17.9.

4. Disconnectbothmulti-plugsfromthealternatorrectifier.

1. Rectifier

2.Multi-plugs

5. Releasethetwoscrewssecuring therectifiertothebatteryboxandwithdrawtherectifier.