The following
is a simple "how-to" guide that should help in your installation of case covers.
You should read all instructions provided and in your shop manual completely before
starting this installation. |
|
 |
|
GENERATOR
COVER |
1. |
Check to make sure your case cover is in good condition
and free of any obvious damage or defect. |
| 2. |
You will need the following items to help with the
installation: |
| |
* Grey "Sensor Safe" Silicon |
|
* Nice strong phillips head screwdriver |
|
* New gasket - Yamaha part # Y5EB-15451-00-00 |
|
*5mm allen wrench or t-handle |
| 3. |
Remove your lower and middle fairings. |
| 4. |
Drain your oil completely. Go ahead and put the drain plug
and filter (if applicable) back in but leave some rags down for any excess oil once the
cover is off. |
| 5. |
Find the stator coil assembly coupler near the shift arm
and disconnect. Remove any zip-ties to make it easier to access. See photo below. |
|
|
| 6. |
Remove the 9 hex bolts holding the cover. |
| 7. |
The cover should come off fairly easily. There are two
dowel pins to guide it in and out. Carefully slide the cover off the generator rotor and
pull the coupler harness out to free the whole thing. See photos below. |
|
|
| 8. |
Now you can remove the stator coil assembly and lead
holder from the inside of the cover. Start with removing the lead holder phillips head
screw. This might be a pain in the ass to get off so be careful. See photo below. |
|
|
| 9. |
Once that pain of a screw is off and the lead holder is
removed...remove the 3 hex bolts holding the stator coil assembly. You can see these in
the above photo. |
| 10. |
Now carefully pull the harness off the cover. It should be
secured with grey silicone. Clean up any residue or dirt in preps for re-application. |
| 11. |
Install the whole stator assembly into the new cover
keeping the same alignment as before. Tighten the 3 hex bolts (using Loc-tite) and
refasten the lead holder. |
| 12. |
Apply grey "sensor safe" silicon to the harness
gasket as seen in the above photo. Make sure there is a good seal before reinstalling. |
| 13. |
Route the coupler harness back into the harness bundle
before installing cover. |
| 14. |
Install the 2 dowel pins into the cover, put the gasket on
the cover and carefully slide the cover into place. This should be an easy process if done
with care and patience. Make sure the gasket doesn't get bunched up or folded anywhere and
makes a good seal. Recheck the silicone on the harness gasket. |
| 15. |
Reconnect the coupler harness, tighten all bolts back to
spec torque (8.7 ft/lb) and recheck the seal around the whole case and that's it! |
|
|
| 16. |
If you are not installing the pickup coil cover: Go ahead
and replenish your oil to proper level and check for leaks after running. |
| 17. |
If you are installing the pickup coil cover: Proceed to
the next section. |
|
|
|
PICKUP
COIL COVER |
|
|
1. |
Check to make sure your case cover is in good condition
and free of any obvious damage or defect. |
| 2. |
You will need the following items to help with the
installation: |
| |
* Grey "Sensor Safe" Silicon |
|
* Nice strong phillips head screwdriver |
|
* New gasket - Yamaha part # Y5EB-15456-00-00 |
|
*5mm allen wrench or t-handle |
| 3. |
Remove your lower and middle fairings. |
| 4. |
Drain your oil completely. Go ahead and put the drain plug
and filter (if applicable) back in but leave some rags down for any excess oil once the
cover is off. |
| 6. |
Remove the 7 hex bolts holding the cover. |
| 7. |
The cover should come off fairly easily. Tap to loosen if
needed. There are two dowel pins to guide it in and out. Carefully slide the cover off the
pickup coil and hold. You can trace this harness back and disconnect beforehand if you
want to. I chose to just do it without disconnecting. |
| 8. |
Now you can remove the pickup coil and lead holder from
the inside of the cover. Start with removing the lead holder phillips head screw. This
might be a pain in the ass to get off so be careful. |
| 9. |
Once that pain of a screw is off and the lead holder is
removed...remove the 2 hex bolts holding the pickup coil. These might also be a pain to
remove. |
| 10. |
Now carefully pull the harness off the cover. It should be
secured with grey silicone. Clean up any residue or dirt in preps for re-application. |
| 11. |
Install the pickup coil into the new cover keeping the
same alignment as before. Tighten the 2 hex bolts (using Loc-tite) and refasten the lead
holder. |
| 12. |
Apply grey "sensor safe" silicon to the harness
gasket. Make sure there is a good seal before reinstalling. |
| 14. |
Install the 2 dowel pins into the cover, put the gasket on
the cover and carefully slide the cover into place. This should be an easy process if done
with care and patience. Make sure the gasket doesn't get bunched up or folded anywhere and
makes a good seal. Recheck the silicone on the harness gasket. |
| 15. |
Tighten all bolts back to spec torque (8.7 ft/lb) and
recheck the seal around the whole case and that's it! |
| 16. |
Go ahead and replenish your oil to proper level and check
for leaks after running. |
|
|
|
|
powered by