Overhaul of the flywheel/generator assembly
Examine the inner part of generator rotor (8) for signs of damage.
Check that the starter clutch is working properly and that the roller races do not show signs of wear or damage of any kind.
Disassemble the unit if you find faulty operation.
Disassembly of the generator flywheel
Unscrew the 8 screws (9) and remove the generator rotor (10) from the flywheel.
Insert two of the screws (9) just removed from the rotor in order to remove the flange (11) and the starter clutch (12) from the flywheel (13).
The starter clutch is a slight interference fit on the flange.
Use a suitable drift to remove it.
Reassembly of the flywheel/generator assembly
Insert the starter clutch (12) in flange (11) bringing the starter clutch edge (A) with chamfered side (B) fully against the flange.
Important
Assemble the components (starter clutch and flange) so that, once assembled, starter clutch edge is on flange chamfered side.
Fit the flange (11) with starter clutch (12) fully home into the flywheel (13), ensuring the centring hole (C) on flange matches the flywheel centring hole (D).
The flange centring hole (C) is the hole with the countersunk lead-in (E).
The centring hole (D) of the flywheel can be either one of the two holes (F).
Note
Use suitable tools to align the centring holes.
Important
Assemble the components (flange and flywheel) so that edge of the starter clutch is enclosed between the flange and flywheel.
Install rotor (10) on flywheel (13), matching one of the two flywheel centring holes (D) with rotor centring hole (G).
The rotor centring hole (G) is the one positioned on the same diameter as the fixing holes (H).
Note
Use suitable tools to align the centring holes.
Smear some threadlocker on the rotor/flywheel retaining screws (26) and start them in their holes.
Tighten screws (26) to a torque of 13 Nm (Min. 11 Nm - Max. 15 Nm), following the specified sequence.
Lubricate the race (L) of the driven gear (4) with engine oil.
Install the driven gear on the starter clutch, ensuring it is properly seated.
Note
To help insertion, turn the driven gear in the direction indicated by the green arrow.
Hold the flywheel (13) with one hand and check that the driven gear can rotate freely in the direction of the green arrow but not in the direction of the red arrow.
If either of these two conditions is not met, this means that the starter clutch has not been installed correctly.