2004 YAMAHA YZF-R1S Service Manual

5-35
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the stator coil assembly
Rider seat
Fuel tank
Left side cowling
Bottom cowlings
Engine oil
Stator coil assembly lead coupler
Plug
Generator rotor cover
Gasket
Dowel pin
Generator rotor assembly
Dowel pin
Bearing housing
Collar1
1
1
1
2
1
2
1
1Remove the parts in the order listed.
Refer to “SEATS” in chapter 3.
Refer to “FUEL TANK” in chapter 3.
Refer to “COWLINGS” in chapter 3.
Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Disconnect.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH AND GENERATOR
STATOR COIL ASSEMBLY
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5-36
STARTER CLUTCH AND GENERATORENG
Order Job / Part Q’ty Remarks
10
11
12
13
14
15Bearing
Stator coil assembly lead holder
Idler gear
Idler gear shaft
Washer
Bearing1
1
1
1
1
1
For installation, reverse the removal
procedure.
10 Nm (1.0 m
kg, 7.2 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
12 Nm (1.2 m
kg, 8.7 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
10 Nm (1.0 m
kg, 7.2 ft
lb)
14 Nm (1.4 m
kg, 10 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
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5-37
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the starter clutch
Generator rotor
Damper
Driven gear
Washer
Starter clutch drive gear
Collar
Washer
Spacer
O-ring1
3
1
1
1
1
1
1
1Remove the parts in the order listed.
For installation, reverse the removal
procedure.
STARTER CLUTCH AND GENERATORENG
STARTER CLUTCH
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5-38
STARTER CLUTCH AND GENERATORENG
NOTE: REMOVING THE GENERATOR
1. Remove:

rider seat

fuel tank
Refer to “SEATS” and “FUEL TANK” in chapter
3.
2. Remove:

left side cowling

bottom cowlings
Refer to “COWLINGS” in chapter 3.
3. Drain:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4. Remove:

plug

generator rotor cover
1

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.
5. Remove:

generator rotor and starter clutch assembly
1.
6. Remove:

idler gear shaft bolt
1

idler shaft

idler gear
2
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5-39
STARTER CLUTCH AND GENERATORENG
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
CHECKING THE DAMPER
1. Check:

dampers
1
Damage / wear
Replace.
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5-40
STARTER CLUTCH AND GENERATORENG
EAS00351
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
a
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.
b. When turning the starter clutch drive gear
counterclockwise
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
clockwise
B, it should turn freely, otherwise
the starter clutch is faulty and must be re-
placed.
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5-41
STARTER CLUTCH AND GENERATORENG
NOTE:
NOTE:
10 Nm (1.0 m
kg, 7.2 ft
lb)
INSTALLING THE STARTER CLUTCH
1. Install:

generator rotor
1

damper 2

driven gear 3

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”.
3. Install:

washer
1

O-ring 2 New

spacer
3
Lubricate the engine oil to O-ring.
INSTALLING THE GENERATOR
1. Install:

idle gear shaft

idle gear
1

washer

idle gear shaft bolt
2
LOCTITE
2. Install:

generator rotor and starter clutch assembly
1
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5-42
STARTER CLUTCH AND GENERATORENG
12 Nm (1.2 m
kg, 8.7 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
NOTE: 3. Install:

generator cover gasket

generator cover
1
(M6 bolts)
(M8 bolts)

First tighten the M8 bolts and then tighten the
M6 bolts.

Tighten the generator rotor cover bolts in
stages and in a crisscross pattern.
4. Fill:

engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
5. Install:

bottom cowling

left side cowling
Refer to “COWLINGS” in chapter 3.
6. Install:

fuel tank

rider seat
Refer to “SEATS” and “FUEL TANK” in chap-
ter 3.
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