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• Apply the sealant to the grommet of
the AC magneto lead.
YAMAHA Bond No. 1215
®
(ThreeBond
No. 1215):
90890-85505
2. Install:
• Starter clutch drive gear "1"
Apply the engine oil on the starter
clutch drive gear inner circumference.
3. Install:
• Starter clutch "1"
To rotor "2".
• Install the starter clutch with its
plate side upward.
• While installing the starter clutch,
push in the projections "a" one by
one on the clutch circumference.
• Push in the starter clutch until it hits
the rotor.
4. Install:
• Starter clutch assembly cover "1"
To rotor "2".
Install the starter clutch assembly
cover by fitting its pawls "a" into the
groove "b" in the rotor.
AC MAGNETO AND STARTER CLUTCH
5. Install:
• Woodruff key "1"
• Rotor "2"
• Degrease the contact surfaces of
the tapered portions of the crank-
shaft and rotor.
• When installing the woodruff key,
make sure that its flat surface "a" is
in parallel with the crankshaft center
line "b".
• When installing the rotor, align the
keyway "c" of the rotor with the
woodruff key.
6. Install:
• Washer (rotor)
• Nut (rotor) "1"
Nut (rotor):
65 Nm (6.5 m•kg, 47
ft•lb)
Use the sheave holder "2"
Tighten the rotor nut to 65 Nm (6.5
m•kg, 47 ft•lb), loosen and retighten
the rotor nut to 65 Nm (6.5 m•kg, 47
ft•lb).
Sheave holder:
YS-1880-A/90890-
01701
7. Install:
• Shaft "1"
• Bearing "2"
• Idle gear 2 "3"
5-49
Apply the engine oil on the shaft,
bearing and idle gear inner circumfer-
ence.
8. Install:
• Dowel pin
• Gasket [crankcase cover (left)]
• Crankcase cover (left) "1"
• Bolt [crankcase cover (left)]
Bolt [crankcase cover
(left)]:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Tighten the bolts in stage, using a
crisscross pattern.
9. Install:
• Washer "1"
• Torque limiter "2"
• Washer
Apply the engine oil to the shaft and
washers.
10. Install:
• Cover (idle gear 1) "1"
• Bolt "2"
Bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Install the cover (idle gear 1) with its
mark "a" facing upward.
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