Yamaha Fz1n Service Manual

							
GENERATOR
5-33
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 bolt10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							
GENERATOR
5-34
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.
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) 
						

							
STARTER CLUTCH
5-35
EAS24550
STARTER CLUTCH
Removing the starter clutch
Order Job/Parts to remove Q’ty Remarks1 Generator rotor 1
2Damper 3
3 Driven gear 1
4 Washer 1
5 Starter clutch drive gear 1
6Collar 1
7 Washer 1
8 Spacer 1
9O-ring 1 For assembly, reverse the removal 
procedure. 
						

							
STARTER CLUTCH
5-36
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”
ET2D1009
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
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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 
counterclockwise “A”, the starter clutch and 
the starter clutch drive gear should engage,  
						

							
STARTER CLUTCH
5-37
otherwise the starter clutch is faulty and 
must be replaced.
c. When turning the starter clutch drive gear  clockwise “B”, it should turn freely, other-
wise the starter clutch is faulty and must be 
replaced.
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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 5-36. 3. Install:
 Washer “1”
 O-ring “2” 
 Spacer “3”
NOTE:
Lubricate the engine oil to O-ring. 
						

							
CRANKSHAFT POSITION SENSOR
5-38
EAS24520
CRANKSHAFT POSITION SENSOR
Removing the crankshaft position sensor
Order Job/Parts to remove Q’ty RemarksRider and passenger seat 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.
1 Crankshaft position sens or lead coupler 1 Disconnect.
2 Crankshaft position sensor 1
3O-ring 1
4 Pickup rotor cover 1
5Gasket 1
6Cover 1 For assembly, reverse the removal 
procedure. 
						

							
CRANKSHAFT POSITION SENSOR
5-39
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 posision sensor 2. Connect
 Crankshaft position sensor lead coupler
Pickup rotor cover12 Nm (1.2 m·kg, 8.7 ft·lb)
Crankshaft position sensor bolt10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE® 
						

							
ELECTRIC STARTER
5-40
EAS24780
ELECTRIC STARTER
Removing the starter motor
Order Job/Parts to remove Q’ty RemarksRider and passenger seat Refer to GENERAL CHASSIS on  page 4-1.
Fuel tank Refer to FUEL TANK on page 7-1.
Throttle body assembly Refer to THROTTLE BODIES on  page 7-4.
1 Starter motor lead 1
2 Starter motor 1 For assembly, reverse the removal 
procedure. 
						

							
ELECTRIC STARTER
5-41
Disassembling the starter motor
Order Job/Parts to remove Q’ty Remarks1O-ring 1
2Front cover 1
3 Lock washer 1
4 Washer 1
5 Starter motor yoke 1
6 Armature assembly 1
7O-ring 2
8 Starter motor lead 2
9 Brush holder 1
10 Rear cover 1 For assembly, reverse the disassem-
bly procedure. 
						

							
ELECTRIC STARTER
5-42
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.
Commutator wear limit 27.0 mm (1.06 in)
Mica undercut0.7 mm (0.03 in)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Armature coilCommutator resistance “1” 0.0250–0.0350  Ω at 20 °C (68 °F)
Insulation resistance “2”
Above 1 M Ω at 20 °C (68 °F)
Brush length wear limit
5.0 mm (0.20 in)
Brush spring force7.65–10.0 N
(780–1021 gf, 27.54–36.03 oz)