Yamaha Tracer MT09TRA - Service manual > Generator and starter clutch

Removing the generator

1. Remove:

• Generator rotor bolt "1"
• Washer

TIP

While holding the generator rotor "2" with the sheave holder "3", loosen the generator rotor bolt.

Sheave holder 90890-01701

Primary clutch holder YS-01880-A

2. Remove:

• Generator rotor "1" (with the flywheel puller "2")
• Woodruff key

NOTICE

To protect the end of the crankshaft, place an appropriate sized socket between the flywheel puller set center bolt and the crankshaft.

TIP

• Install the flywheel puller bolts to the threaded holes of the starter clutch.
• Make sure the flywheel puller is centered over the generator rotor.

Flywheel puller 90890-01362

Heavy duty puller YU-33270-B

Removing the starter clutch

1. Remove:

• Starter clutch bolts
• Starter clutch

TIP

While holding the generator rotor "1" with the sheave holder "2", loosen the starter clutch bolts.

Sheave holder 90890-01701

Primary clutch holder YS-01880-A

Checking the starter clutch

1. Check:

• Starter clutch rollers Damage/wear → Replace.

2. Check:

• Starter clutch idle gear
• Starter clutch gear Burrs/chips/roughness/wear → Replace the defective part(s).

3. Check:

• Starter clutch gear contact surfaces Damage/pitting/wear → Replace the starter clutch gear.

4. Check:

• Starter clutch operation

a. Install the starter clutch gear "1" onto the gen-erator rotor "2" and hold the generator rotor.

b. When turning the starter clutch gear clockwise "A", the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.

c. When turning the starter clutch gear counterclockwise "B", it should turn freely, otherwise the starter clutch is faulty and must be replaced.

Installing the starter clutch

1. Install:

• Starter clutch "1"

Starter clutch bolt 32 Nm (3.2 m*kgf, 23 ft*lbf) LOCTITE

TIP

• Install the starter clutch so that the side of the starter clutch roller assembly with the arrow mark "a" is toward the generator rotor "2".
• While holding the generator rotor with the sheave holder "3", tighten the starter clutch bolts.

Sheave holder 90890-01701

Primary clutch holder YS-01880-A

Installing the generator

1. Install:

• Woodruff key
• Generator rotor
• Washer
• Generator rotor bolt

TIP

• Clean the tapered portion of the crankshaft and the generator rotor hub.
• When installing the generator rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft.
• Lubricate the washer with engine oil.
• Lubricate the generator rotor bolt threads and washer mating surfaces with engine oil.

2. Tighten:

• Generator rotor bolt "1"

Generator rotor bolt 75 Nm (7.5 m*kgf, 54 ft*lbf)

TIP

While holding the generator rotor "2" with the sheave holder "3", tighten the generator rotor bolt.

Sheave holder 90890-01701

Primary clutch holder YS-01880-A

3. Apply:

• Sealant (onto the stator coil assembly lead grommet)

Yamaha bond No. 1215 90890-85505 (Three bond No.1215)

4. Install:

• Generator cover gasket
• Generator cover

Generator cover bolt "1" 12 Nm (1.2 m*kgf, 8.7 ft*lbf) LOCTITE

Generator cover bolt "2" 12 Nm (1.2 m*kgf, 8.7 ft*lbf)

TIP

Tighten the generator cover bolts in stages and in a crisscross pattern.

5. Connect:

• Stator coil coupler
• Crankshaft position sensor coupler

TIP

To route the stator coil lead, refer to "CABLE ROUTING"

Electric starter

Checking the starter motor

1. Check:

• Commutator

Dirt → Clean with 600 grit sandpaper.

2. 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.

Mica undercut (depth) 0.70 mm (0.03 in)

TIP

The mica of the commutator must be undercut to ensure proper operation of the commutator.

3. Measure:

• Armature assembly resistances (commutator and insulation) Out of specification → Replace the starter motor.

a. Measure the armature assembly resistances with the digital circuit tester.

Digital circuit tester 90890-03174

Model 88 Multimeter with tachometer YU-A1927

Armature coil resistance 0.0050-0.0150 Ω Insulation resistance Above 1 MΩ at 20 ºC (68 ºF)

b. If any resistance is out of specification, replace the starter motor.

1. Commutator resistance

2. Insulation resistance

4. Measure:

• Brush length "a".

  Out of specification →  Replace the brush holder set.

Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in)

5. Measure:

• Brush spring force.

  Out of specification → Replace the brush holder set

Brush spring force 6.03-6.52 N (615-665 gf, 21.71- 23.47 oz)

6. Check:

• Gear teeth. Damage/wear → Replace the starter motor.

7. Check:

• Bearing
• Oil seal

Damage/wear → Replace the starter motor.

Assembling the starter motor

1. Install:

• Brush holder set
• Insulator "1"

TIP

Install the insulator as shown in the illustration.

2. Install:

• Starter motor rear cover "1"
• Starter motor yoke "2"
• Starter motor front cover "3"

TIP

Align the match marks "a" on the starter motor yoke with the match marks "b" on the front and rear cover.

Installing the starter motor

1. Install:

• Starter motor "1"
• Negative battery lead "2"
• Starter motor bolts "3"

TIP

Install the negative battery lead as shown in the illustration.

Starter motor bolt 12 Nm (1.2 m*kgf, 8.7 ft*lbf)

2. Connect:

• Starter motor lead

See also: