Yamaha Fz6 N Service Manual

GENERATOR AND STARTER CLUTCH
5-30
EAS24490
REMOVING THE GENERATOR
1. Remove:Seat
Refer to GENERAL CHASSIS on page 4-
1.
 Fuel tank
Refer to FUEL TANK on page 7-1.
2. Drain:  Coolant
Refer to CHANGING THE COOLANT on 
page 3-20.
 Engine oil
Refer to CHANGING THE ENGINE OIL 
on page 3-14.
3. Remove:
 Generator rotor cover
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.
4. Remove: Generator rotor bolt “1”...

GENERATOR AND STARTER CLUTCH
5-31
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  “a”
Damage/pitting/wear  → Replace the starter 
clutch gear.
4. Check:  Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear “1” onto  the...

GENERATOR AND STARTER CLUTCH
5-32
EAS24500
INSTALLING THE GENERATOR
1. Install: Generator rotor
 Washer 
 Generator rotor bolt
NOTE:
 Clean the tapered portion of the crankshaft 
and the generator rotor hub.
 Replace the washer with a new one.
2. Tighten: Generator rotor bolt “1”
NOTE:
 While holding the generator rotor “2” with the sheave holder “3”, tighten the generator rotor 
bolt.
 Do not allow the sheave holder to touch the 
projection on the generator rotor.
3. Apply:  Sealant (onto the...

PICKUP ROTOR
5-33
EAS4S81015
PICKUP ROTOR
Removing the pickup rotor
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel (with cowlin g) Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel (with cowling) 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 3-14.
Generator rotor cover Refer to GENERATOR AND STARTER 
CLUTCH on page 5-28.
1...

PICKUP ROTOR
5-34
EAS4S81041
REMOVING THE PICKUP ROTOR
1. Remove: Pickup 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.
2. Remove: Pickup rotor bolt “1”
 Washer “2”
 Pickup rotor “3”
NOTE:
While holding the generator rotor “4” with the 
sheave holder “5”, loosen the pickup rotor bolt.
EAS4S81042
INSTALLING THE PICKUP ROTOR
1. Install: Pickup rotor “1”
Washer
 Pickup rotor bolt
NOTE:...

PICKUP ROTOR
5-35
3. Apply: Sealant (onto the crankshaft position sensor lead 
grommet)
4. Install:  Pickup rotor cover gasket 
 Pickup rotor cover
NOTE:
 When installing the pickup rotor cover, align the timing chain guide (intake side) pin “1” 
with the hole “2” in the pickup rotor cover.
 Tighten the pickup rotor cover bolts in stages 
and in a crisscross pattern.
Yamaha bond No. 1215
(Three Bond No.1215
®)
90890-85505
New 

ELECTRIC STARTER
5-36
EAS24780
ELECTRIC STARTER
Removing the starter motor
Order Job/Parts to remove Q’ty RemarksSeat Refer to GENERAL CHASSIS on page 4-1.
Right front cowling inner panel (with cowlin g) Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel (with cowling) Refer to GENERAL CHASSIS on page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Throttle body Refer to THROTTLE BODIES on page 7-4.
1 Starter motor lead 1
2 Starter motor 1 For installation, reverse the removal proce-...

ELECTRIC STARTER
5-37
Disassembling the starter motor
Order Job/Parts to remove Q’ty Remarks1O-ring 1
2 Starter motor front cover 1
3 Lock washer 1
4 Oil seal 1
5 Bearing 1
6 Washer set 1
7 Starter motor rear cover 1
8 Washer set 1
9O-ring 2
10 Brush holder 1
11 Armature assembly 1
12 Starter motor yoke 1
13 O-ring 2 For assembly, reverse the disassembly pro-
cedure. 

ELECTRIC STARTER
5-38
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...

ELECTRIC STARTER
5-39
7. Check: Gear teeth Damage/wear  → Replace the gear.
8. Check:
 Bearing
Oil seal Damage/wear  → Replace the defective 
part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:  Brush seat “1”
2. Install:  Armature “2”
 O-ring “3” 
NOTE:
Align the tab “a” on the brush seat with the slot 
“b” in the starter motor yoke.
3. Install:
 Starter motor yoke “1”
 O-ring “2” 
 Starter motor front cover “3”
 Starter motor rear cover “4”
 Starter motor assembling bolts “5”
NOTE:...