zaphoid18
XS400 Enthusiast
Hi guys,
Through a recent minor screw up which I will detail later I had to remove my rotor and starter clutch again, this time I thought to document it.
If you are pushing your starter button and can hear the starter spin and chain rattle behind the alternator case but its not grabbing the engine, your starter clutch is likely damaged.
Step 1
Drain the oil out of the engine for simplicity (this step may not be necessary but you will lose some oil out of the left case when removing the alternator cover)
Step 2
remove the left foot pedal, shift lever and clutch plate cover. Now remove the alternator cover carefully and watch to see that the gasket comes away cleanly and is not torn during removal.
Step 3
stop engine from turning by placing a suitable metal screwdriver or rod through the rotor and brace it against some wood. Remove the rotor bolt with a 17mm socket.
Step 4
Insert the "yamaha rotor extractor tool" into the exposed threads being careful not to cross thread the bolt. The bolt is a 16mm x 1.5 pitch right hand thread and can be purchased from parts n more for 9 dollars under the "tools" tab.
The general feeling i've gathered from everyone online and common sense is DO NOT use a 2 or 3 arm puller to get the rotor off. It may work but you risk damaging the case, best to use the right tool for the job
.
Before tightening the removal bolt the engine must be stopped from turning in the opposite direction since you will be tightening the bolt to pop off the rotor
Step 5
keep tightening and the rotor will pull itself from its tapered shaft
DO NOT loose the woodruff key, its a little half moon piece that acts as a guide for the rotor on installation
Through a recent minor screw up which I will detail later I had to remove my rotor and starter clutch again, this time I thought to document it.
If you are pushing your starter button and can hear the starter spin and chain rattle behind the alternator case but its not grabbing the engine, your starter clutch is likely damaged.
Step 1
Drain the oil out of the engine for simplicity (this step may not be necessary but you will lose some oil out of the left case when removing the alternator cover)
Step 2
remove the left foot pedal, shift lever and clutch plate cover. Now remove the alternator cover carefully and watch to see that the gasket comes away cleanly and is not torn during removal.
Step 3
stop engine from turning by placing a suitable metal screwdriver or rod through the rotor and brace it against some wood. Remove the rotor bolt with a 17mm socket.
Step 4
Insert the "yamaha rotor extractor tool" into the exposed threads being careful not to cross thread the bolt. The bolt is a 16mm x 1.5 pitch right hand thread and can be purchased from parts n more for 9 dollars under the "tools" tab.
The general feeling i've gathered from everyone online and common sense is DO NOT use a 2 or 3 arm puller to get the rotor off. It may work but you risk damaging the case, best to use the right tool for the job
. Before tightening the removal bolt the engine must be stopped from turning in the opposite direction since you will be tightening the bolt to pop off the rotor
Step 5
keep tightening and the rotor will pull itself from its tapered shaft
DO NOT loose the woodruff key, its a little half moon piece that acts as a guide for the rotor on installation
the rotors are different between points and electronic ignition
