Starter motor turns, but engine does not turn

• Faulty starter clutch

• Damaged reduction gear

• Damaged starter driven gear

• Damaged or faulty starter motor pinion gear

 

COMPONENT LOCATION

 

128 N·m (13.1 kgf·m, 94 lbf·ft)

 

13-2

ALTERNATOR/STARTER CLUTCH

 

LEFT CRANKCASE COVER

 

REMOVAL

 

Drain the engine oil (page 3-9).

 

Remove the following:

 

– Left side cover (page 2-3)

– Drive sprocket cover (page 2-6)

– Gearshift pedal (page 12-14)

 

Disconnect the following:

 

– Alternator 3P connector [1]

– CKP sensor/neutral switch 3P (Black) connector [2]

 

Release the alternator wire [3] from the clamp [4].

 

 

Disconnect the neutral switch connector [1] and release the wire from the left crankcase cover groove.

 

The left crankcase Loosen the left crankcase cover bolts [2] in a crisscross cover (stator) is pattern in 2 or 3 steps and remove the bolts and left

 

magnetically crankcase cover [3]. attracted to the

flywheel, be careful during removal.

 

 

Remove the dowel pins [1] and gasket [2].

 

 

INSTALLATION

 

Be careful not to Clean any gasket material from the mating surfaces of damage the mating the left crankcase and cover.

^surfaces. Install the dowel pins [1] and a new gasket [2].

 

[1] _[3]

 

[2]

[2]

 

 

[3]

[2]

 

 

[1]

 

[2]

 

[1]

 

 

[4]

 

 

[1]

 

13-3

ALTERNATOR/STARTER CLUTCH

 

The left crankcase cover (stator) is magnetically attracted to the flywheel, be careful during installation.

 

Install the left crankcase cover [1] and bolts [2]. Tighten the bolts in a crisscross pattern in 2 or 3 steps.

 

Connect the neutral switch connector [3] and set the wire into the left crankcase cover groove.

 

 

Connect the following:

 

– Alternator 3P connector [1]

– CKP sensor/neutral switch 3P (Black) connector [2]

 

Secure the alternator wire [3] with the clamp [4]. Install the following:

– Gearshift pedal (page 12-17)

– Drive sprocket cover (page 2-6)

– Left side cover (page 2-3)

 

Fill the engine with the recommended engine oil (page 3-9).

 

[2]

 

[1]

[3]

 

[1] _[3]

 

 

		[4]
[2]

 

STATOR/CKP SENSOR

 

REMOVAL/INSTALLATION

 

Remove and install the stator/CKP sensor as following illustration.

 

• Apply locking agent to the CKP sensor mounting bolt threads as specified (page 1-12).

 

• Apply sealant to the alternator/CKP sensor wire grommet sealing surface (page 1-15).

10 N·m (1.0 kgf·m, 7 lbf·ft)
	10 N·m (1.0 kgf·m, 7 lbf·ft)

 

STATOR/CKP SENSOR

 

 

GROMMET

 

 

LEFT CRANKCASE COVER

 

13-4

ALTERNATOR/STARTER CLUTCH

 

FLYWHEEL

 

REMOVAL

 

Remove the left crankcase cover (page 13-3). Remove the starter reduction gear [1] and shaft [2].

 

 

Hold the flywheel with the special tool and remove the flywheel bolt [1] and washer [2].

 

TOOL:
[3] Flywheel holder	07725-0040001

 

 

Remove the flywheel [1] using the special tool.

 

TOOL:
[2] Flywheel puller	07733-0020001

 

Remove the needle bearing [1].

 

Be careful not to Remove the woodruff key [2]. damage the key

groove and crankshaft.

 

 

[1]

 

[2]

		[2]		[1]
[3]

 

[1]

 

 

[2]

[2]

 

 

[1]

 

 

13-5

ALTERNATOR/STARTER CLUTCH

INSPECTION

 

Inspect the following parts for scratch, damage, abnormal wear and deformation. Replace if necessary.

 

– Starter reduction gear shaft

– Starter reduction gear

– Woodruff key

– Needle bearing

 

INSTALLATION

 

Apply molybdenum oil solution to the needle bearing [1] rotating area.

 

Install the needle bearing onto the crankshaft. Clean any oil from the crankshaft taper surface.

 

Be careful not to Install the woodruff key [2] onto the crankshaft. damage the key

groove and crankshaft.

 

Install the flywheel while aligning the woodruff key on the crankshaft with flywheel keyway.

 

Apply engine oil to the flywheel bolt [1] threads and seating surface.

 

Install the washer [2] and bolt.

 

Hold the flywheel with a special tool and tighten the bolt to the specified torque.

 

TOOL:
[3] Flywheel holder	07725-0040001

 

TORQUE:128 N·m (13.1 kgf·m, 94 lbf·ft)

 

[1]

 

[1]

 

[3]

 

 

[2]

 

 

Align

 

 

[2]

 

 

13-6

ALTERNATOR/STARTER CLUTCH

 

Apply molybdenum oil solution to the starter reduction gear shaft [1] outer surface and starter reduction gear [2] inner surface.

 

Install the shaft and starter reduction gear. Install the left crankcase cover (page 13-3).

 

STARTER CLUTCH

 

REMOVAL

 

Remove the flywheel (page 13-5).

 

Make sure that the starter driven gear [1] turns counterclockwise smoothly and does not turn clockwise.

 

Remove the starter driven gear while turning it counterclockwise.

 

 

Hold the flywheel with a special tool and remove the
[2]
starter clutch socket bolt [1].
TOOL:
[2] Flywheel holder	07725-0040001

 

Remove the starter clutch outer and starter one-way clutch.

 

INSPECTION

 

Inspect the following parts for scratch, damage, abnormal wear and deformation. Replace if necessary.

 

– Starter driven gear

 

Measure each part according to ALTERNATOR/ STARTER CLUTCH SPECIFICATIONS (page 1-7). Replace any part if it is out of service limit.

[2]

 

[1]

 

[1]

 

 

[1]

 

13-7

ALTERNATOR/STARTER CLUTCH

INSTALLATION

STARTER DRIVEN GEAR

 

STARTER CLUTCH OUTER

 

 

STARTER ONE-WAY CLUTCH

 

 

FLYWHEEL

 

 

30 N·m (3.1 kgf·m, 22 lbf·ft)

 

Apply engine oil to the starter one-way clutch [1] sprag.
	[1]
Install the starter one-way clutch to the starter clutch
outer [2].
Install the starter clutch assembly to the flywheel [3] as
shown.

 

[2]

 

		[3]
Apply locking agent to the starter clutch socket bolts [1]
		[1]
threads.
Install the starter clutch socket bolts.
Hold the flywheel with a special tool and tighten the
socket bolts to the specified torque.
TOOL:
[2] Flywheel holder	07725-0040001

TORQUE:30 N·m (3.1 kgf·m, 22 lbf·ft)

 

[2]

 

13-8

ALTERNATOR/STARTER CLUTCH

Apply engine oil to the starter driven gear [1] sliding surface.

Install the starter driven gear while turning it counterclockwise.

 

[1]

 

Make sure that the starter driven gear turns counterclockwise smoothly and does not turn clockwise.

Install the flywheel (page 13-6).

 

 

13-9

MEMO