7-30 2006 Buell Lightning: Electrical
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ALTERNATOR 7.8
REMOVAL/DISASSEMBLY
1WARNING1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
1. Disconnect negative battery cable.
2. Remove primary cover. See 6.2 PRIMARY COVER.
3. Remove clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. See 6.5 PRIMARY
CHAIN.
4. Remove/disassemble rotor and/or stator, as required.
Refer to the following procedures.
Rotor
1. See Figure 7-34. Remove the eight fasteners which
secure alternator rotor to engine sprocket.
2. See Figure 7-35. Position blocking under rotor. Press
sprocket free of rotor.
NOTE
Resistance to sprocket/rotor disassembly is due in part to the
magnetic force of the permanent rotor magnets.
Stator
1. See Figure 7-36. Disconnect stator wiring (4) from volt-
age regulator wiring at connector (5) [46] under sprocket
cover. See 7.26 SPROCKET COVER WIRING.
2. Remove cable straps holding stator wire to wire harness.
NOTE
Stator TORX screws contain a thread locking compound. Do
not reuse existing screws. Always use new screws with the
proper thread locking compound. Loss of torque on TORX
fasteners could result in alternator damage.
3. Remove and discard the four TORX screws (1) which
secure stator (2) to left crankcase half.
4. Remove retainer plate fasteners.
5. Remove stator wiring grommet (3) from left crankcase
half.
6. Withdraw stator wiring (4) from grommet hole in left
crankcase half. Remove stator.
Figure 7-34. Rotor Assembly
Figure 7-35. Removing Rotor From Sprocket
Figure 7-36. Stator Assembly
8739
8610
1. Stator fastener (4)
2. Stator
3. Grommet
4. Stator wiring
5. Connector [46]
b1094x7x
2
4
1
23
5
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