GENERATOR

Removing the stator coil assembly

* Yamaha bond No. 1215 (Three bond No. 1215®)

Order

Job/Parts to remove

Q’ty

Remarks

 

Engine oil

 

Drain.

Refer to CHANGING THE ENGINE OIL.

 

Seat

 

Refer to GENERAL CHASSIS.

 

Shroud (left)

 

Refer to GENERAL CHASSIS.

1

Stator coil assembly coupler

1

Disconnect.

2

Crankshaft position sensor coupler

1

Disconnect.

3

Shift pedal

1

 

4

Crankcase cover (left)

1

 

5

Gasket

1

 

6

Dowel pin

2

 

7

Holder

1

 

8

Stator coil assembly

1

 

9

Generator rotor

1

 

10

Woodruff key

1

 

REMOVING THE GENERATOR

1.Remove:

  • Nut (generator rotor) “1”

  • Washer

2.Remove:

  • Generator rotor “1”

    (with the rotor puller “2”)

  • Woodruff key

  • Rotor puller

    90890-04151

  • Rotor puller

    YM-04151

CHECKING THE GENERATOR

1.Check:

  • Generator rotor “1” inner surface “a”

  • Stator coil assembly “2” outer surface “b”

    Damage → Inspect the crankshaft runout and crankshaft bearing.

CHECKING THE WOODRUFF KEY

1.Check:

  • Woodruff key “1”

    Damage → Replace.

INSTALLING THE GENERATOR

1.Install:

  • Stator coil assembly “1”

  • Screw (stator coil assembly) “2”

  • Screw (stator coil assembly)

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

    LOCTITE®

  • Crankshaft position sensor “3”

  • Bolt (crankshaft position sensor) “4”

  • Holder

  • Bolt (holder)

  • Bolt (crankshaft position sensor)

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

    LOCTITE®

  • Bolt (holder)

    8 N·m (0.8 kgf·m, 5.9 lb·ft)

    LOCTITE®

  • Apply the sealant to the grommet of the stator coil assembly lead.

  • Tighten the stator coil assembly screws using the T25 bit.

  • Pass the stator coil assembly lead through the crankcase cover side.

  • Yamaha bond No. 1215

    90890-85505

  • Three bond No. 1215®

2.Install:

  • Woodruff key “1”

  • Generator rotor “2”

  • Clean the contact surfaces of the tapered portions of the crankshaft and generator rotor.

  • When installing the woodruff key, make sure that its flat surface “a” is in parallel with the crankshaft center line “b”.

  • When installing the generator rotor, align the keyway “c” of the generator rotor with the woodruff key.

3.Install:

  • Washer

  • Nut (generator rotor) “1”

  • Nut (generator rotor)

    65 N·m (6.5 kgf·m, 48 lb·ft)

4.Install:

  • Dowel pin “1”

  • Gasket (crankcase cover (left)) “2”

  • Crankcase cover (left) “3”

  • Holder “4”

  • Crankcase cover bolt (left) “5”

  • Crankcase cover bolt (left)

    10 N·m (1.0 kgf·m, 7.4 lb·ft)

Tighten the bolts in stages and in a crisscross pattern.

5.Connect:

  • Stator coil assembly lead

Refer to CABLE ROUTING DIAGRAM.