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8. STARTER MOTOR/GENERATOR/LEFT CRANK-
CASE COVER/STARTER CLUTCH/CAMSHAFT Pulsar CK 125
SERVICE INFORMATION....................... 8-1 CAMSHAFT REMOVAL..............................8-4
TROUBLESHOOTING.............................. 8-1 CAMSHAFT INSTALLATION ....................8-5
STARTER MOTOR REMOVAL............... 8-2 STARTER CLUTCH INSTALLATION .......8-5
LEFT CRANKCASE COVER REMOVAL .... 8-2 GENERATOR INSTALLATION..................8-5
GENERATOR REMOVAL........................ 8-2 LEFT CRANKCASE COVER INSTALLATION....8-6
STARTER CLUTCH REMOVAL ............. 8-3 STARTER MOTOR INSTALLATION.........8-6
SERVICE INFORMATION
GENERAL INSTRUCTIONS
· The starter motor, generator, left crankcase and starter clutch can be serviced in the frame.
· Do not install the starter clutch forcedly.
· Install the generator by aligning the groove in the flywheel with the key on the crankshaft.
· Install the starter motor reduction gear shaft by aligning the shaft pin with the shaft seat groove.
SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Reduction gear shaft O.D. 9.9729.987 9.932
Reduction gear shaft hole I.D. 10.03110.056 10.096
Reduction pinion shaft O.D. 9.9669.984 9.926
Reduction pinion shaft hole I.D. 10.03110.056 10.096
Roller O.D. (42.19542.208)10.1910.205 (42.248) 10.15
Starter gear shaft I.D. 22.0122.022 22.062
Starter gear shaft O.D. (42.19542.208) 36.97537 (42.155) 36.935
TORQUE VALUE
Flywheel lock bolt 4.05.2kg-m
SPECIAL TOOLS
Flywheel holder E021
Flywheel puller E005
TROUBLESHOOTING
Hard starting/Poor performance at high speed
· Improperly tightened flywheel lock bolt Starting noise
· Worn reduction pinion
Starter clutch slips · Worn starter gear
· Worn starter clutch roller · Worn starter clutch roller
· Faulty starter clutch roller or spring · Faulty reduction gear shaft bearing
· Worn starter gear shaft O.D.
8-1