Yamaha Fz1n Service Manual

GENERATOR
5-33
EAS24490
REMOVING THE GENERATOR
1. Remove:Plug
 Generator rotor cover “1”
NOTE:
 While pushing generator rotor, remove the 
generator rotor cover.
 Loosen each bolt 1/4 of a turn a time, in 
stages and in a crisscross pattern.
 After all of the bolts are fully loosened, 
remove them.
2. Remove:  Generator rotor and starter clutch assem-bly “1”
3. Remove:  Idle gear shaft bolt “1”
 Idle shaft
 Idle gear “2”
EAS24500
INSTALLING THE GENERATOR
1. Install: Idle gear shaft
 Idle gear...

GENERATOR
5-34
NOTE:
 First tighten the M8 bolts and then tighten the M6 bolts.
 Tighten the generator rotor cover bolts in 
stages and in a crisscross pattern.
Generator rotor cover bolt (M6)
12 Nm (1.2 m·kg, 8.7 ft·lb)
Generator rotor cover bolt (M8)
22 Nm (2.2 m·kg, 16 ft·lb) 

STARTER CLUTCH
5-35
EAS24550
STARTER CLUTCH
Removing the starter clutch
Order Job/Parts to remove Q’ty Remarks1 Generator rotor 1
2Damper 3
3 Driven gear 1
4 Washer 1
5 Starter clutch drive gear 1
6Collar 1
7 Washer 1
8 Spacer 1
9O-ring 1 For assembly, reverse the removal 
procedure. 

STARTER CLUTCH
5-36
EAS24560
REMOVING THE STARTER CLUTCH
1. Remove: Spacer “1”
 O-ring “2”
 Washer “3”
2. Remove:  Starter clutch drive gear “1”
 Collar “2”
 Washer “3”
3. Remove:  Driven gear “1”
 Dampers “2”
 Generator rotor “3”
ET2D1009
CHECKING THE DAMPER
1. Check:
 Dampers “1”Damage/wear  → Replace.
EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
 Starter clutch rollers “1”
Damage/wear  → Replace.
2. Check:  Starter clutch idle gear “1”
 Starter clutch drive gear “2”...

STARTER CLUTCH
5-37
otherwise the starter clutch is faulty and 
must be replaced.
c. When turning the starter clutch drive gear  clockwise “B”, it should turn freely, other-
wise the starter clutch is faulty and must be 
replaced.
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EAS24600
INSTALLING THE STARTER CLUTCH
1. Install: Generator rotor “1”
 Damper “2”
 Driven gear “3”
NOTE:
 The hole side of the damper is installed to the generator side.
 Lubricate the engine oil “4”.
2. Install
 Starter clutch drive gear...

CRANKSHAFT POSITION SENSOR
5-38
EAS24520
CRANKSHAFT POSITION SENSOR
Removing the crankshaft position sensor
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Engine oil Drain. Refer to CHANGING THE ENGINE 
OIL on page 3-12.
1 Crankshaft position sens or lead coupler 1 Disconnect.
2 Crankshaft position sensor 1
3O-ring 1
4 Pickup rotor cover 1
5Gasket 1
6Cover 1 For assembly, reverse the removal 
procedure. 

CRANKSHAFT POSITION SENSOR
5-39
EAS24530
REMOVING THE CRANKSHAFT POSITION 
SENSOR
1. Disconnect: Crankshaft position sensor lead coupler
2. Remove:  Crankshaft position sensor
O-ring
 Pickup coil rotor cover “1”
NOTE:
Loosen each bolt 1/4 of a turn at a time, in 
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove 
them.
EAS24540
INSTALLING THE CRANKSHAFT POSITION 
SENSOR
1. Install:
Gasket 
 Pickup rotor cover “1”
 O-ring 
 Crankshaft posision sensor 2....

ELECTRIC STARTER
5-40
EAS24780
ELECTRIC STARTER
Removing the starter motor
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Throttle body assembly Refer to THROTTLE BODIES on  page 7-4.
1 Starter motor lead 1
2 Starter motor 1 For assembly, reverse the removal 
procedure. 

ELECTRIC STARTER
5-41
Disassembling the starter motor
Order Job/Parts to remove Q’ty Remarks1O-ring 1
2Front cover 1
3 Lock washer 1
4 Washer 1
5 Starter motor yoke 1
6 Armature assembly 1
7O-ring 2
8 Starter motor lead 2
9 Brush holder 1
10 Rear cover 1 For assembly, reverse the disassem-
bly procedure. 

ELECTRIC STARTER
5-42
EAS24790
CHECKING THE STARTER MOTOR
1. Check: Commutator
Dirt  → Clean with 600 grit sandpaper.
2. Measure:  Commutator diameter “a”
Out of specification  → Replace the starter 
motor.
3. Measure:  Mica undercut “a”
Out of specification  → Scrape the mica to 
the proper measurement with a hacksaw 
blade that has been grounded to fit the 
commutator.
NOTE:
The mica of the commutator must be undercut 
to ensure proper operation of the commutator.
4. Measure:  Armature assembly...