8. STARTER MOTOR/GENERATOR/LEFT CRANK- CASE COVER/STARTER CLUTCH/CAMSHAFT Pulsar CK 125 SERVICE INFORMATION....................... 8-1 CAMSHAFT REMOVAL..............................8-4 TROUBLESHOOTING.............................. 8-1 CAMSHAFT INSTALLATION ....................8-5 STARTER MOTOR REMOVAL............... 8-2 STARTER CLUTCH INSTALLATION .......8-5 LEFT CRANKCASE COVER REMOVAL .... 8-2 GENERATOR INSTALLATION..................8-5 GENERATOR REMOVAL........................ 8-2 LEFT CRANKCASE COVER INSTALLATION....8-6 STARTER CLUTCH REMOVAL ............. 8-3 STARTER MOTOR INSTALLATION.........8-6 SERVICE INFORMATION GENERAL INSTRUCTIONS · The starter motor, generator, left crankcase and starter clutch can be serviced in the frame. · Do not install the starter clutch forcedly. · Install the generator by aligning the groove in the flywheel with the key on the crankshaft. · Install the starter motor reduction gear shaft by aligning the shaft pin with the shaft seat groove. SPECIFICATIONS Item Standard (mm) Service Limit (mm) Reduction gear shaft O.D. 9.9729.987 9.932 Reduction gear shaft hole I.D. 10.03110.056 10.096 Reduction pinion shaft O.D. 9.9669.984 9.926 Reduction pinion shaft hole I.D. 10.03110.056 10.096 Roller O.D. (42.19542.208)10.1910.205 (42.248) 10.15 Starter gear shaft I.D. 22.0122.022 22.062 Starter gear shaft O.D. (42.19542.208) 36.97537 (42.155) 36.935 TORQUE VALUE Flywheel lock bolt 4.05.2kg-m SPECIAL TOOLS Flywheel holder E021 Flywheel puller E005 TROUBLESHOOTING Hard starting/Poor performance at high speed · Improperly tightened flywheel lock bolt Starting noise · Worn reduction pinion Starter clutch slips · Worn starter gear · Worn starter clutch roller · Worn starter clutch roller · Faulty starter clutch roller or spring · Faulty reduction gear shaft bearing · Worn starter gear shaft O.D. 8-1