Honda Crf250l Service Manual

							12-18
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CLUTCH/GEARSHIFT LINKAGEINSTALLATION
Apply engine oil to the primary drive gear [1] teeth.
Install the primary drive gea r while aligning its punch
mark with the crankshaft punch mark.
Install the washer [1].
Apply engine oil to the primary drive gear lock nut [2]
threads and seating surface, then install it.
Temporarily install the washer [1], clutch outer guide
[2], needle bearing [3] and clutch outer [4].
Insert the gear holder [5] between the primary drive and
driven gears.
Tighten the primary drive gear lock nut [6] to the
specified torque.
Install the clutch assembly (page 12-11).
[1]
Align
[1]
[2]
TOOL:
Gear holder, M1.5 07724-0010200
TORQUE: 108 N·m (11.0 kgf·m, 80 lbf·ft)
[5][1]/[2]/[3]/[4][6] 
						

							13-1
13
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13. ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION ···························13-2
TROUBLESHOOTING·································13-2
COMPONENT LOCATION ··························13-2
LEFT CRANKCASE COVER ··················\
····13-3STATOR/CKP SENSOR ····························· 13-4
FLYWHEEL ················································· 13-5
STARTER CLUTCH ···································· 13-7 
						

							13-2
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ALTERNATOR/STARTER CLUTCH
ALTERNATOR/STARTER CLUTCHSERVICE INFORMATION
GENERAL
 • This section covers the removal and installation of the flywheel, alternator and starter clutch. These services can be done with
the engine installed in the frame.
TROUBLESHOOTING
Starter motor turns, bu t 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) 
						

							13-3
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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.
Loosen the left crankcase cover bolts [2] in a crisscross
pattern in 2 or 3 steps and remove the bolts and left
crankcase cover [3].
Remove the dowel pins  [1] and gasket [2].
INSTALLATION
Be careful not to
damage the mating
surfaces.Clean any gasket material from the mating surfaces of
the left crankcase and cover.
Install the dowel pins [1] and a new gasket [2].
[1]
[2]
[3]
[4]
The left crankcasecover (stator) is
magnetically
attracted to the
flywheel, be careful
during removal.
[1]
[2]
[3]
[2]
[1]
[2]
[1] 
						

							13-4
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ALTERNATOR/STARTER CLUTCH
The left crankcasecover (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 cr ankcase cover groove.
Connect the following:
– Alternator 3P connector [1]
– CKP sensor/neutral switch 3P (Black) connector [2]
Secure the alternator wi re [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).
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).
[3]
[2]
[1]
[1]
[2]
[3]
[4]
GROMMET
10 N·m (1.0 kgf·m, 7 lbf·ft)10 N·m (1.0 kgf·m, 7 lbf·ft)
STATOR/CKP SENSOR
LEFT CRANKCASE COVER 
						

							13-5
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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].
Remove the flywheel [1] using the special tool.
Remove the needle bearing [1].
Remove the woodruff key [2].[1]
[2]
TOOL:
[3] Flywheel holder07725-0040001
[3][1][2]
TOOL:
[2] Flywheel puller 07733-0020001
[1]
[2]
Be careful not to
damage the key groove andcrankshaft.
[2]
[1] 
						

							13-6
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ALTERNATOR/STARTER CLUTCHINSPECTION
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.
Install the woodruff key [2] onto the 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.
Be careful not todamage the key
groove andcrankshaft.
[2]
[1]
Align
TOOL:
[3] Flywheel holder 07725-0040001
TORQUE: 128 N·m (13.1 kgf·m, 94 lbf·ft)
[1][2]
[3] 
						

							13-7
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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
starter clutch socket bolt [1].
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]
TOOL:
[2] Flywheel holder 07725-0040001
[2]
[1] 
						

							13-8
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ALTERNATOR/STARTER CLUTCHINSTALLATION
Apply engine oil to the starter one-way clutch [1] sprag.
Install the starter one-way clutch to the starter clutch
outer [2].
Install the starter cl utch assembly to the flywheel [3] as
shown.
Apply locking agent to the starter clutch socket bolts [1]
threads.
Install the starter clutch socket bolts.
Hold the flywheel with a special tool and tighten the
socket bolts to the specified torque.
30 N·m (3.1 kgf·m, 22 lbf·ft)
STARTER DRIVEN GEAR
FLYWHEEL
STARTER CLUTCH OUTER
STARTER ONE-WAY CLUTCH
[1]
[2]
[1]
[3]
TOOL:
[2] Flywheel holder 07725-0040001
TORQUE: 30 N·m (3.1 kgf·m, 22 lbf·ft)
[2]
[1] 
						

							13-9
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ALTERNATOR/STARTER CLUTCH
Apply engine oil to the starter driven gear [1] sliding
surface.
Install the starter driven gear while turning it
counterclockwise.
Make sure that the starter driven gear turns
counterclockwise smoothly and does not turn
clockwise.
Install the flywheel (page 13-6).
[1]