Yamaha Yzf R1 2007 Manual
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GENERATOR 5-31 12 Stator coil assembly lead holder 1 13 Idler gear 1 14 Idler gear shaft 1 15 Washer 1 16 Bearing 1 For installation, reverse the removal proce- dure. Removing the generator Order Job/Parts to remove Q’ty Remarks
GENERATOR 5-32 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 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE® 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) New
GENERATOR 5-33 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.
STARTER CLUTCH 5-34 EAS24550 STARTER CLUTCH Removing the starter clutch Order Job/Parts to remove Q’ty Remarks 1 Generator rotor 1 2 Damper 3 3 Driven gear 1 4 Washer 1 5 Starter clutch drive gear 1 6 Collar 1 7 Washer 1 8Spacer 1 9O-ring 1 For assembly, reverse the removal proce- dure.
STARTER CLUTCH 5-35 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” EAS4C81007 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.
STARTER CLUTCH 5-36 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. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 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 5-35.3. Install: Washer “1” O-ring “2” Spacer “3” NOTE: Lubricate the engine oil to O-ring. New
CRANKSHAFT POSITION SENSOR 5-37 EAS24520 CRANKSHAFT POSITION SENSOR Removing the crankshaft position sensor Order Job/Parts to remove Q’ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4-1. Side cowlings Refer to GENERAL CHASSIS on page 4-1. Lower cowlings Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. Engine oilDrain. Refer to CHANGING THE ENGINE OIL on page 3-11. 1 Crankshaft position sensor lead coupler 1 2 Crankshaft position sensor 1 3O-ring 1 4 Pickup rotor cover 1 5Gasket 1 6Cover 1 For installation, reverse the removal proce- dure.
CRANKSHAFT POSITION SENSOR 5-38 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 position sensor2. Connect Crankshaft position sensor lead coupler Pickup rotor cover 12 Nm (1.2 m·kg, 8.7 ft·lb) Crankshaft position sensor bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE® New New
ELECTRIC STARTER 5-39 EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Rider seat Refer to GENERAL CHASSIS on page 4-1. Fuel tank Refer to FUEL TANK on page 7-1. Air filter case Refer to GENERAL CHASSIS on page 4-1. Throttle body Refer to THROTTLE BODIES on page 7-4. 1 Starter motor lead 1 Disconnect. 2 Starter motor 1 For installation, reverse the removal proce- dure.
ELECTRIC STARTER 5-40 Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks 1O-ring 1 2Front cover 1 3 Lock washer 1 4 Washer 1 5 Star ter motor yoke 1 6 Armature assembly 1 7Gasket 2 8 Brush holder 1 9 Rear cover 1 For assembly, reverse the removal proce- dure.