Yamaha Fz1n Service Manual
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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 “1” Washer Idle gear shaft bolt “2” 2. Install Generator rotor and starter clutch assem-bly “1” 3. Install: Generator rotor cover gasket Generator rotor cover “1” Idle gear shaft bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
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” Burrs/chips/roughness/wear → Replace the defective part(s). 3. Check: Starter clutch gear’s contacting surfaces Damage/pitting/wear → Replace the starter clutch gear. 4. Check: Starter clutch operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter clutch drive gear “1” onto the starter clutch “2” and hold the starter clutch. b. When turning the starter clutch drive gear counterclockwise “A”, the starter clutch and the starter clutch drive gear should engage,
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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 “1” Collar “2” Washer “3”Refer to CHECKING THE STARTER CLUTCH on page 5-36. 3. Install: Washer “1” O-ring “2” Spacer “3” NOTE: Lubricate the engine oil to O-ring.
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. Connect Crankshaft position sensor lead coupler Pickup rotor cover12 Nm (1.2 m·kg, 8.7 ft·lb) Crankshaft position sensor bolt10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE®
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 resistances (commuta-tor and insulation) Out of specification → Replace the starter motor. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure the armature assembly resis- tances with the pocket tester. b. If any resistance is out of specification, replace the starter motor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: Brush length “a”Out of specification → Replace the brushes as a set. 6. Measure: Brush spring force Out of specification → Replace the brush springs as a set. Commutator wear limit 27.0 mm (1.06 in) Mica undercut0.7 mm (0.03 in) Pocket tester 90890-03112 Analog pocket tester YU-03112-C Armature coilCommutator resistance “1” 0.0250–0.0350 Ω at 20 °C (68 °F) Insulation resistance “2” Above 1 M Ω at 20 °C (68 °F) Brush length wear limit 5.0 mm (0.20 in) Brush spring force7.65–10.0 N (780–1021 gf, 27.54–36.03 oz)