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”
 Washer
NOTE:
 While holding the generator rotor “2” with the 
sheave holder “3”, loosen the generator rotor 
bolt.
 Do not allow the sheave holder to touch the 
projection on the generator rotor.
5. Remove:  Generator rotor “1” (with the flywheel puller “2” and flywheel 
puller attachment)
 Woodruff key
CAUTION:
ECA13880
To protect the end of the crankshaft, place 
an appropriate sized socket between the 
flywheel puller set’s center bolt and the 
crankshaft.
NOTE:
Make sure the flywheel puller is centered over 
the generator rotor.
EAS24560
REMOVING THE STARTER CLUTCH
1. Remove:  Starter clutch bolt “1”
NOTE:
 While holding the generator rotor with the sheave holder, remove the starter clutch bolt.
 Do not allow the sheave holder to touch the 
projection on the generator rotor.
Sheave holder 90890-01701
Primary clutch holder
YS-01880-A
Flywheel puller90890-01362
Heavy duty puller
YU-33270-B
Flywheel puller attachment 90890-04089
Crankshaft protector YM-33282
Sheave holder90890-01701
Primary clutch holder
YS-01880-A 
						

							
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
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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  clockwise “A”, the starter clutch and the 
starter clutch drive gear should engage,  otherwise the starter clutch is faulty and 
must be replaced.
c. When turning the starter clutch drive gear  counterclockwise “B”, it should turn freely, 
otherwise the starter clutch is faulty and 
must be replaced.
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EAS24600
INSTALLING THE STARTER CLUTCH
1. Install: Starter clutch
NOTE:
 While holding the generator rotor “1” with the sheave holder “2”, tighten the starter clutch 
bolt.
 Do not allow the sheave holder to touch the 
projection on the generator rotor.
Starter clutch bolt 32 Nm (3.2 m·kg, 23 ft·lb)
LOCTITE
®
Sheave holder90890-01701
Primary clutch holder
YS-01880-A 
						

							
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 stator coil assembly lead grom-
met) 4. Install:
Stator coil
5. Install:
 Generator rotor cover
NOTE:
Tighten the generator rotor cover bolts in 
stages and in a crisscross pattern.
6. Fill: Engine oil Refer to CHANGING THE ENGINE OIL 
on page 3-14.
 Coolant Refer to CHANGING THE COOLANT on 
page 3-20.
7. Install: Fuel tank Refer to FUEL TANK on page 7-1.
Seat Refer to GENERAL CHASSIS on page 4-
1.
Generator rotor bolt75 Nm (7.5 m·kg, 54 ft·lb)
Sheave holder90890-01701
Primary clutch holder YS-01880-A
New
Yamaha bond No. 1215
(Three bond No.1215
®)
90890-85505
Timing plate bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) 
						

							
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 Crankshaft position sensor lead coupler 1 Disconnect.
2 Pickup rotor cover 1
3 Pickup rotor cover gasket 1
4Dowel pin 2
5 Crankshaft position sensor 1
6Pickup rotor 1
7Cover 1
For assembly, reverse the removal proce-
dure. 
						

							
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:
When installing the pickup rotor, align the 
groove “a” in the crank shaft sprocket with the 
projection “b” in the pickup rotor.
2. Tighten:
 Pickup rotor bolt “1”
NOTE:
While holding the generator rotor “2” with the 
sheave holder “3”, tighten the pickup rotor bolt.
Sheave holder 90890-01701
Primary clutch holder YS-01880-A
Pickup rotor bolt35 Nm (3.5 m·kg, 25 ft·lb)
Sheave holder90890-01701
Primary clutch holder YS-01880-A 
						

							
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-
dure. 
						

							
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 resistances (commuta- tor and insulation)
Out of specification  → Replace the starter 
motor.
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a. Measure the armature assembly resis- tances with the pocket tester.
b. If any resistance is out of specification,  replace the starter motor.
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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.
Limit 27.0 mm (1.06 in)
Mica undercut (depth)0.70 mm (0.03 in)
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
Armature coilCommutator resistance “1”
0.0012–0.0022  Ω at 20 °C (68 °F)
Insulation resistance “2” Above 1 M Ω at 20 °C (68 °F)
Limit
3.50 mm (0.14 in)
Brush spring force7.16–9.52 N (25.77–34.27 oz)
(730–971 gf) 
						

							
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:
Align the match marks “a” on the starter motor 
yoke with the match marks “b” on the starter 
motor front and rear covers.
EAS24810
INSTALLING THE STARTER MOTOR
1. Install: Starter motor
 Starter motor bolts
2. Connect:  Starter motor lead
Starter motor assembling bolt 3.4 Nm (0.34 m·kg, 2.5 ft·lb)
New
New
Starter motor bolt10 Nm (1.0 m·kg, 7.2 ft·lb)