Yamaha XMAX YP125R - Service manual > Starter clutch and generator (YP125R)

Removing the generator cover and stator coil
Removing the generator cover and stator coil

Removing the generator rotor and starter clutch
Removing the generator rotor and starter clutch

Removing the generator

1. Remove:

TIP

Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

2. Remove:

TIP

Sheave holder 90890-01701

Primary clutch holder YS-01880-A

Removing the generator

3. Remove:

NOTICE

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

TIP

Make sure the flywheel puller is centered over the generator rotor.

Flywheel puller 90890-01362

Heavy duty puller YU-33270-B

Removing the generator

Removing the starter clutch

1. Remove:

TIP

Sheave holder 90890-01701

Primary clutch holder YS-01880-A

Removing the starter clutch

Checking the starter clutch

1. Check:

Damage/wear → Replace.

Checking the starter clutch

2. Check:

Burrs/chips/roughness/wear → Replace the defective part(s).

3. Check:

Damage/pitting/wear → Replace the starter clutch gear.

4. Check:

a. Install the starter clutch gear "1" onto the starter clutch and hold the generator rotor.

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

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

Checking the starter clutch

Installing the starter clutch

1. Install:

Starter clutch bolt 13 Nm (1.3 m*kgf, 9.4 ft*lbf) LOCTITE

TIP

Sheave holder 90890-01701

Primary clutch holder YS-01880-A

Installing the starter clutch

Installing the generator

1. Install:

TIP

2. Tighten:

Generator rotor nut 80 Nm (8.0 m*kgf, 58 ft*lbf)

TIP

Sheave holder 90890-01701

Primary clutch holder YS-01880-A

Installing the generator

3. Apply:

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

Installing the generator

4. Install:

Oil seal installed depth 4.5-5.4 mm (0.18-0.21 in)

Installing the generator

a. Oil seal installed depth

5. Install:

Generator cover bolt 10 Nm (1.0 m*kgf, 7.2 ft*lbf)

TIP

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

Electric starter (YP125R)

Removing the starter motor
Removing the starter motor

Disassembling the starter motor
Disassembling the starter motor

Checking the starter motor

1. Check:

Dirt → Clean with 600 grit sandpaper.

2. Measure:

Out of specification → Replace the starter motor.

Limit 16.6 mm (0.65 in)

Checking the starter motor

3. Measure:

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) 1.35 mm (0.05 in)

TIP

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

Checking the starter motor

4. Measure:

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

Commutator resistance "1" Continuity (0.0378-0.0462 Ω at 20 ºC (68 ºF))

Insulation resistance "2" No continuity (Above 1 MΩ at 20 ºC (68 ºF))

Checking the starter motor

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

5. Measure:

Out of specification → Replace the brushes as a set.

Limit 3.50 mm (0.14 in)

Checking the starter motor

6. Measure:

Out of specification → Replace the brush springs as a set.

Brush spring force 3.92-5.88 N (400-600 gf, 14.11- 21.17 oz)

7. Check:

Damage/wear → Replace the gear.

8. Check:

Damage/wear → Replace the defective part(s).

See also:

 Yamaha XMAX YP125R - Service manual > V-belt automatic transmission (YP125R)

Removing the V-belt case cover Removing the V-belt, primary sheave and secondary sheave

 Yamaha XMAX YP125R - Service manual > Oil pump (YP125R)

Removing the oil pump Checking the oil pump 1. Check: Oil pump drive gear Oil pump driven gear Oil pump housing Oil pump housing cover

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