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 startor 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 3-12.
 Coolant
Refer to CHANGING THE COOLANT on 
page 3-18.
7. Install:
Fuel tankRefer 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 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 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 holder90890-01701
Primary clutch holder YS-01880-A
Pickup rotor bolt
35 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 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 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.
Limit 27.0 mm (1.06 in)
Mica undercut (depth)0.70 mm (0.03 in)
Pocket tester90890-03112
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 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:
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 bolt3.4 Nm (0.34 m·kg, 2.5 ft·lb)
New
New
Starter motor bolt
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							
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 gasket 1
9 Oil pipe 1
10 Oil delivery pipe 1
11 Oil pump assembly 1
12 Dowel pin 2 
						

							
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