94
FI576A
FI578
REPLACING STARTER GEAR
BEARING
1. Support the starter clutch gear in a press making sure
to support the hub around the entire circumference;
then using a suitable bearing driver, press the bearing
from the gear.
FI583
2. Thoroughly clean the gear hub; then apply a drop of
green Loctite #620 to the bearing outer race and
press into the gear hub until even with the lower
chamfer radius.
FI580
INSPECTING STATOR COIL/
MAGNETO COVER ASSEMBLY
1. Inspect the stator coil for burned or discolored wir-
ing, broken or missing hold-down clips, or loose cap
screws.
2. Inspect the bearings in the magneto housing for dis-
coloration, roughness when rotated, and secure fit in
bearing bores.
REPLACING STATOR COIL/
CRANKSHAFT POSITION SENSOR
1. Remove the three cap screws securing the stator coil,
two cap screws securing the crankshaft position sen-
sor, and one cap screw from the harness hold-down.
2. Lift the rubber grommet out of the housing; then
remove the stator coil/crankshaft position sensor.
Account for and note the position of the harness
hold-down under the crankshaft position sensor.
FI590
3. Install the new stator coil assembly and secure with
three new “patch-lock” cap screws. Tighten to 13 ft-
lb.
4. Place the stator wire harness hold-down into posi-
tion; then install the crankshaft position sensor and
secure with two cap screws. Tighten securely.
5. Install the upper cable hold-down and secure with a
cap screw. Tighten securely.
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