Engine start and battery charging system of motorcycle Yamaha YZF-R1 Y(C) (2009-2014)

Removing the generator
Order Job/Parts to remove Quantity Remarks Fuel tank Refer to " Fuel tank ". Air filter case Refer to " Air filter case ". Side cowling Refer to " General chassis ". Stator coil lead coupler Refer to " General chassis ". 1 Generator cover 1 2...

Removing generator
1. Remove: Generator cover Generator cover gasket Dowel pins 2. Remove: Generator rotor bolt "1" Washer While holding the generator rotor "2" with the sheave holder "3", loosen the generator rotor bolt. Sheave holder 908990890-01701. Primary clutch...

Installing the generator
1. Install: Stator coil assembly Stator coil lead holder Stator coil assembly bolt 14 Nm (1.4 m·kgf, 10 ft·lbf). Stator coil lead holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf). 2. Install: Generator rotor Washer IN·W Generator rotor bolt Clean the...

Removing the starter clutch
Order Job/Parts to remove Quantity Remarks Clutch housing assembly Refer to " Clutch ". 1 Starter clutch gear 1 2 Bearing 1 3 Starter clutch holder 1 4 Starter clutch 1 5 Starter idle gear 1 For installation, reverse the removal procedure.

Removing starter clutch
1. Remove: Starter clutch bolt "1" While holding the clutch housing assembly "2" with the sheave holder "3", remove the starter clutch bolt. Fix the flat surface of the clutch housing assembly with the sheave holder. Sheave holder 90890-01701....

Checking the starter clutch
1. Check: Starter clutch rollers "1". Damage/wear → Replace. 2. Check: Starter clutch gear "1" Starter idle 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: Starter clutch Starter clutch holder bolt 14 Nm (1.4 m·kgf, 10 ft·lbf). While holding the clutch housing assembly "1" with the sheave holder "2", tighten the starter clutch holder bolt "3". Fix the flat surface of the clutch housing...

Removing the pickup rotor
Order Job/Parts to remove Quantity Remarks Fuel tank Refer to " Fuel tank ". Generator cover Refer to " Generator ". Air filter case Refer to " Air filter case ". 1 Timing check bolt 1 2 Pickup rotor cover 1 1 3 O-ring 1 4 Dowel pin 2 5 Crankshaft...

Removing pickup rotor
1. Remove: Pickup rotor bolt "1" Washer Pickup rotor While holding the generator rotor "2" with the sheave holder "3", loosen the pickup rotor bolt. Sheave holder 90890-01701. Primary clutch holder YS-01880-A.

Installing the pickup rotor
1. Install: Pickup rotor "1" Washer Pickup rotor bolt When installing the pickup rotor, align the woodruff key "a" with the groove "b" on the pickup rotor. Face the "K" mark on the pickup rotor outer side of the vehicle and install. 2. Tighten:...

Removing the starter motor
Order Job/Parts to remove Quantity Remarks Battery negative lead Refer to " General chassis ". Fuel tank Refer to " Fuel tank ". Air filter case Refer to " Air filter case ". Throttle body Refer to " Throttle bodies ". Engine outlet pipe Refer to "...

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 Gasket 2 8 Brush holder 1 9 O-ring 1 10 Rear cover 1 For installation, reverse the removal procedure.

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. Limit 23.5 mm (0.93 in). 3. Measure: Mica undercut "a" Out of specification → Scrape the mica to the...

Assembling the starter motor
1. Install: Brush holder Armature assembly Nut 5 Nm (0.5 m·kgf, 3.6 ft·lbf). O-ring New. a. Pull both the brush spring "1" and the brush "2" outside and hook the brush spring to the groove portion at the side of the brush. b. Insert the armature...

Circuit diagram of gnition system
1. Main switch; 4. Main fuse; 7. Battery; 8. Fuel injection system fuse; 11. Relay unit; 14. Sidestand switch; 20. ECU (engine control unit); 21. Ignition coil #1; 22. Ignition coil #2; 23. Ignition coil #3; 24. Ignition coil #4; 25. Spark plug; 40....

Engine stopping due to sidestand operation
When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch...

Ignition system — troubleshooting
The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Air filter case duct 4. Side cowlings 1. Check the fuses. (Main, ignition and fuel...

Circuit diagram of electric starting system
1. Main switch; 4. Main fuse; 7. Battery; 9. Starter relay; 10. Starter motor; 11. Relay unit; 12. Starting circuit cut-off relay; 14. Sidestand switch; 62. Right handlebar switch; 65. Engine stop switch; 66. Start switch; 67. Gear position sensor;...

Starting circuit cutoff system operation
If the engine stop switch is set to "q" and the main switch is set to "ON" (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the gear position sensor is...

Electric starting system — troubleshooting
The starter motor fails to turn. Before troubleshooting, remove the following part(s): 1. Rider seat 2. Passenger seat 3. Heat protector 4. Side cowlings 1. Check the fuses. (Main and ignition) Refer to " Checking the fuses ". → Replace the fuse(s)....

Charging system — circuit diagram
2. AC magneto; 3. Rectifier/regulator; 4. Main fuse; 7. Battery; 95. Engine ground; 96. Battery negative lead

Charging system — troubleshooting
The battery is not being charged. Before troubleshooting, remove the following part(s): 1. Rider seat 2. Right side cowling 1. Check the fuse. (Main) Refer to " Checking the fuses ". → Replace the fuse. 2. Check the battery. Refer to " Checking and...

Checking and charging the battery
Warning: Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near...

Checking the starter motor operation
1. Check: Starter motor operation Does not operate → Perform the electric starting system troubleshooting, starting with step 4. Refer to " Troubleshooting ". a. Connect the positive battery terminal "1" and starter motor lead "2" with a jumper lead...

Checking the stator coil
1. Disconnect: Stator coil coupler (from the wire harness) 2. Check: Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.112-0.168 at 20°C (68°F) a. Connect the pocket tester ( x 1) to the stator coil...

Checking the rectifier/regulator
1. Check: Rectifier/regulator input voltage Out of specification → Correct the stator coil condition. Refer to " Checking the stator coil ". Rectifier/regulator input voltage above 14 V at 5000 r/min. a. Set the engine tachometer to the ignition...