Engine start and battery charging system of motorcycle Yamaha FZ1 (2006-2015)

Removing the generator
Order Job/Parts to remove Quantity Remarks Rider and passenger seat Refer to « General chassis ». Fuel tank Refer to « Fuel tank ». Engine oil Drain. Refer to « Changing the engine oil ». 1 Stator coil assembly lead coupler 1 Disconnect. 2 Plug 1 3...

Installing the generator
1. Install: Idle gear shaft Idle gear «1» Washer Idle gear shaft bolt «2» Idle gear shaft bolt: 10 Nm (1.0 m·kg, 7.2 ft·lb). 2. Install: Generator rotor and starter clutch assembly «1» 3. Install: Generator rotor cover gasket Generator rotor cover...

Removing the starter clutch
Order Job/Parts to remove Quantity 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 8 Spacer 1 9 O-ring 1 1. Remove: Spacer «1» O-ring «2» Washer «3» 2. Remove: Starter clutch...

Checking the damper
1. Check: Dampers «1» Damage/wear → Replace.

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....

Installing the starter clutch
1. Install: Generator rotor «1» Damper «2» Driven gear «3» Notes: 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...

Removing the starter motor
Order Job/Parts to remove Quantity Remarks Rider and passenger seat Refer to « General chassis ». Fuel tank Refer to « Fuel tank » on page 7-1. Throttle body assembly Refer to « Throttle bodies ». 1 Starter motor lead 1 2 Starter motor 1

Disassembling the starter motor
Order Job/Parts to remove Quantity Remarks 1 O-ring 1 2 Front cover 1 3 Lock washer 1 4 Washer 1 5 Starter motor yoke 1 6 Armature assembly 1 7 O-ring 2 8 Starter motor lead 2 9 Brush holder 1 10 Rear cover 1

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. Commutator wear limit: 27.0 mm (1.06 in). 3. Measure: Mica undercut «a» Out of specification → Scrape...

Assembling the starter motor
1. Install: Brush seat «1» Note: Align the tab «a» on the brush seat with the tab «b» in the starter motor rear cover. 2. Install: Armature «1» 3. Install: Starter motor yoke «1» O-rings «2» Starter motor rear cover «3» Starter motor assembling...

Installing the starter motor
1. Install: Starter motor «1» Starter motor bolts «2» Starter motor bolt: 10 Nm (1.0 m·kg, 7.2 ft·lb). 2. Connect: Starter motor lead «3