Explanation:Unlike other models, whenever the generator rotor is removed on XVS1100 models, the rear cylinder camshaft tim-ing must be set during the disassembly and reassembly procedure.
Below is a step-by-step procedure that is easy to follow.
DISASSEMBLY:1. From the left side of the engine, rotate the crankshaft clockwise until the rear cylinder (#1 cylinder) is at Top
Dead Center (TDC) compression. The rear cylinder is at TDC compression when the “T” mark on the generator rotor aligns with the center of the timing inspection hole in the generator cover (FIG. 1) and the reference mark on the camshaft is aligned with the alignment boss on the cylinder head (FIG. 2).
FIG. 1
FIG. 2
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2. Remove the generator cover.
FIG. 3
3. The cam chain drive gear is a scissor-type (zero lash) gear and requires inserting a punch into an alignment hole to align its gear teeth during generator rotor removal.
In some cases, the alignment hole may not be in a position that allows inserting a punch. If this is the case, rotate the crankshaft clockwise 2-turns (720°) until the reference mark on the camshaft is again aligned with the alignment boss on the cylinder head. Check if the alignment hole in the cam chain drive gear is in a position that allows a punch to be inserted. If not, continue to turn the crankshaft 2-turns at a time until the hole is in a position that allows the punch to be inserted as shown (it may require multiple turns of the crankshaft).
CAM CHAIN DRIVE GEAR WITH PUNCH INSERTED
IT TAKES 2 TURNS OF THE CRANKSHAFT FOR THESE MARKS TO REALIGN.
IT TAKES 10 TURNS OF THE CRANKSHAFT FOR THESE MARKS TO REALIGN.
FIG. 4
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4. Remove the generator rotor.
NOTE: Reach behind the rotor and hold the dampened drive gear and generator rotor together, then remove as an assembly.
Place a rag under and behind the generator rotor during removal just in case the drive gear comes off the generator rotor to prevent the 6-damper springs and dowels for the drive gear from falling into the engine (FIG. 5)
Also, do not turn the crankshaft or the cam chain drive gear (zero lash gear) during or after generator rotor removal (FIG. 6). This prevents verifying the rear cylinder is timed 435˚ after the front cylinder.
REASSEMBLY:
1. If the drive gear has come off the generator rotor, install 2 damper springs and 2 limiter dowels (6 total) into each of the 3 slots in the generator rotor and install the drive onto the generator rotor. Make sure the punch mark on the drive gear is aligned with the woodruff key groove in the generator rotor. Make sure the 3 engage-ment dogs are centered between the damper springs and dowels in the generator rotor.
3. Install the generator rotor taking care to align the teeth of the drive gear with the teeth of the cam chain drive gear. Also, make sure the thrust washer is on the shift shaft.
NOTE: If using a new cam chain drive gear, it’s supplied with a 6mm dowel already in the hole. Don’t forget to remove it after installation.
4. Temporarily install the generator rotor-retaining nut and washer and lightly tighten the nut to hold the generator rotor.
5. Temporarily install the left engine cover and ensure the line next to the “T” on the generator rotor is aligned with the center of the timing inspection hole (this is TDC rear cylinder). Also, be sure the reference mark on the camshaft is aligned with the mark on the cylinder head.
NOTE: If the timing marks do not align, either the cam chain drive gear or crankshaft moved during disassembly. Remove the generator rotor and move the cam chain drive gear as needed to provide correct cam timing.
6. Remove the left side engine cover again and torque the generator rotor nut to specification (175 Nm [17.5 m-kg, 127 ft-lb]). Reassemble the unit using a new left side cover gasket.
