Check
1. Trace the wiring back from the alternator cover on the left-hand side of the engine and disconnect it the wiring connector containing the three yellow wires - on XL600V models, remove the seat, on XL650V and XRV750-P models onwards (1993-on) remove the lefthand side panel, and on XRV750-L to N (1990 to 1992) models remove the right-hand side panel to access the connector (see illustrations). Check the connector terminals for corrosion and security.
![](https://motoinstruction.ru/img/honda/19/126128.jpg)
32.1a. Alternator wiring connector (arrowed) - XL600V
![](https://motoinstruction.ru/img/honda/19/126129.jpg)
32.1b. Alternator wiring connector - XL650V
![](https://motoinstruction.ru/img/honda/19/126130.jpg)
32.1c. Alternator wiring connector (A), pulse generator wiring connector (B) - XRV750
2. Using a multimeter set to the ohms x 1 (ohmmeter) scale measure the resistance between each of the yellow wires on the alternator side of the connector, taking a total of three readings, then check for continuity between each terminal and ground (earth). If the stator coil windings are in good condition the three readings should be within the range shown in the Specifications at the start of this Chapter, and there should be no continuity (Infinite resistance) between any of the terminals and ground (earth). If not, the alternator stator coil assembly is at fault and should be replaced with a new one. Note: Before condemning the stator coils, check the fault is not due to damaged wiring between the connector and the coils.
Removal
Note: The alternator rotor bolt has left-hand threads. This means it has to be slackened and tightened in the OPPOSITE direction to normal bolts. Turn the bolt clockwise to unscrew it. and anti-clockwise to tighten it.
3. On XL600V and XRV750 models remove the left-hand fairing side panel, and on XL650V models remove the fairing - although they do not actually restrict access on any model, if they're not there they can't be damaged should a tool slip when loosening and tightening the alternator rotor bolt. On all models remove the belly pan (see Chapter 8) and the front sprocket cover (see Chapter 6).
4. Either dram the engine oil (see Chapter 1), or place a container under the engine to catch the oil that will come out when the alternator cover is removed. If your model has a centrestand place the bike on it so that It is level - this minimises oil loss. If your model does not have a centrestand and you do not have an auxiliary stand it is best to drain the oil.
5. Trace the wiring back from the alternator cover on the left-hand side of the engine and disconnect it the wiring connector containing the three yellow wires - on XL600V models, remove the seat, on XL650V and XRV750-P models onward (1993-on) remove the lefthand side panel, and on XRV750-L to N (1990 to 1992) models remove the right-hand side panel to access the connector (see illustration 32.1a, bore). Release the wiring from any clips or ties. On XRV750 models also disconnect the pulse generator coil wiring connector - on L to N (1990 to 1992) models you will have to remove the fuel tank to access it (see Chapter 4), on all other models it is on the right of the alternator connector (see illustration 32.1c).
6. Working in a criss-cross pattern, evenly slacken the alternator cover bolts (see Illustration). Lift the cover away from the engine, noting that it will be restrained by the force of the rotor magnets, and be prepared to catch any residual oil. Remove the gasket and discard it. Remove the dowels from either the cover or the crankcase if it is loose.
![](https://motoinstruction.ru/img/honda/19/126131.jpg)
32.6. Alternator cover bolts (arrowed)
7. Withdraw the starter drive gear shaft from the crankcase and remove the gear, noting which way round it fits (see illustration). Withdraw the idle/reduction gear shaft from the crankcase and remove the gear, noting which way round it fits.
![](https://motoinstruction.ru/img/honda/19/126132.jpg)
32.7. Withdraw the shafts (arrowed) and remove the gears
8. To remove the rotor bolt it is necessary to stop the rotor from turning. The best way is to use a commercially available rotor strap (see illustration). If one is not available, try placing the transmission in gear and having an assistant apply the rear brake hard. Unscrew the bolt, remembering that it has left-hand threads (see Note above), and noting that it is very tight. Note the washer fitted with the bolt.
![](https://motoinstruction.ru/img/honda/19/126133.jpg)
32.8. Using a rotor strap to hold the rotor while unscrewing the bolt
9. To remove the rotor from the shaft it is necessary to use a rotor puller. Thread the rotor puller into the centre of the rotor and turn it until the rotor is displaced from the shaft, holding the rotor to prevent the engine turning. Remove the Woodruff key from its slot in the crankcase if it is loose, and if required slide the needle bearing off the shaft (see illustrations). Separate the starter clutch from the rotor if required (see Chapter 2).
![](https://motoinstruction.ru/img/honda/19/126134.jpg)
32.9a. Remove the Woodruff key if it is loose...
![](https://motoinstruction.ru/img/honda/19/126135.jpg)
32.9b ...and slide the bearing off the shaft
10. To remove the stator from the cover, unscrew the bolts securing the stator, and the bolt securing the wiring clamp, then remove the assembly, noting how the rubber wiring grommet fits (see illustration).
![](https://motoinstruction.ru/img/honda/19/126136.jpg)
32.10. Unscrew the stator bolts (A) and the wiring clamp bolt (B) and free the § grommet (C)
Installation
11. Fit the stator into the cover, aligning the rubber wiring grommet with the groove (see illustration 32.10). Apply a suitable nonpermanent thread locking compound to the stator bolt threads. Install the bolts and tighten them to the torque setting specified at the beginning of the Chapter. Apply a suitable sealant to the wiring grommet, then press it into the cut-out in the cover. Secure the wiring with its clamp and tighten the bolt securely.
12. If separated, fit the starter clutch onto the back of the rotor (see Chapter 2), Apply some oil to the needle bearing and slide it onto the end of the crankshaft (see illustration 32.9b).
13. Clean the tapered end of the crankshaft and the corresponding mating surface on the inside of the rotor with a suitable solvent. Fit the Woodruff key into its slot in the crankshaft it removed (see illustration). Make sure that no metal objects have attached themselves to the magnet on the inside of the rotor. Slide the rotor onto the shaft, making sure the groove on the inside of the rotor is aligned with and fits over the Woodruff key. Make sure the Woodruff key does not become dislodged when installing the rotor.
![](https://motoinstruction.ru/img/honda/19/126137.jpg)
32.13. Fit the Woodruff key into its slot
14. Apply some clean oil to the rotor bolt threads and the underside of the head. Install the rotor bolt with its washer, making sure the slightly raised centre of the washer is facing the bolt, and tighten it to the torque setting specified at the beginning of the Chapter, using the method employed on removal to prevent the rotor from turning, and not forgetting it has left-hand threads (see illustrations).
![](https://motoinstruction.ru/img/honda/19/126138.jpg)
32.14a. Install the bolt with its washer...
![](https://motoinstruction.ru/img/honda/19/126139.jpg)
32.14b ...and tighten it to the specified torque
15. Lubricate the idle/reduction gear shaft with clean engine oil. Position the gear In the crankcase, making sure the smaller pinion faces inwards and its teeth mesh correctly with the teeth of the starter driven gear, then slide the shaft into the gear (see illustration). Lubricate the starter drive gear shaft with clean engine oil. Position the gear in the crankcase, making sure the OUT mark faces outwards and its teeth mesh correctly with the teeth of the idle/reduction gear and the starter motor shaft, then slide the shaft into the gear (see illustration).
![](https://motoinstruction.ru/img/honda/19/126140.jpg)
32.15a. Install the idle/reduction gear...
![](https://motoinstruction.ru/img/honda/19/126141.jpg)
32.15b ...and the starter drive gear
16. Fit the dowels into the crankcase it removed. Install the alternator cover using a new gasket, making sure they locate onto the dowels, and that the bores in the cover locate onto the idle/reduction and starter drive gear shafts (see illustrations). Tighten the cover bolts evenly in a criss-cross sequence.
![](https://motoinstruction.ru/img/honda/19/126142.jpg)
32.16a. Locate the new gasket onto the dowels (arrowed)...
![](https://motoinstruction.ru/img/honda/19/126143.jpg)
32.16b ...then install the cover...
![](https://motoinstruction.ru/img/honda/19/126144.jpg)
32.16c ...making sure the gear shafts locate in their bores (arrows)
17. Reconnect the wiring at the connector(s) and secure it with any clips or ties previously released (see illustration 32.1a, b or c).
18. Fill the engine with oil, or top it up to the correct level, according to you removal method (see Chapter 1). Install the front sprocket cover, belly pan and any other components also removed.