![background image](/i/kawasaki/160046/kawasaki-er5-2004/h/kawasaki-er5-2004-283.png)
ELECTRICAL SYSTEM 15-25
Charging System
•
Holding the rotor [A] steady, remove the Allen bolts [B] to
separate the rotor and starter clutch [C].
Starter Clutch Sprocket Removal
•
Remove:
Alternator cover (see Alternator Rotor/Starter Clutch Re-
moval)
Alternator rotor with Starter Clutch (see Alternator Ro-
tor/Starter Clutch Removal)
•
Remove the woodruff key [A] and spacer [B].
•
Remove the starter chain guide [C] with the guide stay
[D].
•
Remove the starter clutch sprocket [E], starter motor
sprocket and starter chain as a set.
•
In case that the starter motor has been removed, do the
following:
○
Remove the starter motor sprocket.
○
Remove the alternator rotor with the starter clutch, starter
clutch sprocket and starter chain as a set.
Starter Clutch Sprocket Installation
•
Apply a thin coat of molybdenum disulfide grease to the
frictional surface between the crankshaft and the starter
clutch sprocket.
•
If the starter motor has been removed, install it first.
•
Install the starter clutch sprocket, starter motor sprocket
and starter chain as a set.
•
Install the alternator rotor with the starter clutch and alter-
nator cover.
Alternator Rotor/Starter Clutch Installation
•
Apply a non-permanent locking agent to the threads of the
starter clutch Allen bolts, and tighten them to the specified
torque in assembling the starter clutch onto the alternator
rotor.
Torque - Starter Clutch Allen Bolts: 34 N·m (3.5 kgf·m, 25
ft·lb)
○
Be careful that the rollers do not drop out of the starter
clutch during assembly.
•
Using a high flash-point solvent, clean off any oil or dirt
that may be on the crankshaft taper [A] and rotor tapered
hole [B].
•
Fit the woodruff key securely in the slot [C] in the crank-
shaft before installing the rotor assembly on the crank-
shaft.