Yamaha FZS6W 07 User Manual

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: Sealart(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 Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel 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.
Generator rotor cover Refer to GENERATOR AND STARTER 
CLUTCH on page 5-28.
1 Crankshaft position sensor lead...

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 90890-85505
(Three Bond No.1215
®)
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 Refer to GENERAL CHASSIS on page 4-1.
Left front cowling inner panel 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:CommutatorDirt  → 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 teethDamage/wear  → Replace the gear.
8. Check:  Bearing
Oil sealDamage/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:...

OIL PUMP
5-40
EAS24920
OIL PUMP
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty RemarksEngine oil Drain.
Refer to CHANGING THE ENGINE OIL on 
page 3-12.
Coolant Drain.
Refer to CHANGING THE COOLANT on 
page 3-18.
Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5-1.
Water pump Refer to WATER PUMP on page 6-9.
1 Oil level switch lead coupler 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4Oil pan 1
5 Oil pan gasket 1
6Dowel pin 2
7 Oil strainer 1
8 Oil strainer...

OIL PUMP
5-41
13 Relief valve assembly 1For installation, reverse the removal proce-
dure.
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty Remarks