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. |
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| 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. |
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| 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. |
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| 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. |
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| 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! |
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| 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 | |
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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. |
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