To replace scratched clutch and generator covers with brand new parts would cost about $130 even with discounted
parts from partsfish.com. One solution is to have the parts professionally
polished at a Polishing House. The cost to have the parts polished and the scratches removed was about $70. The
disadvantage is that the polished aluminum will require more maintenance than the painted parts to preserve their
appearance.
From partsfish.com the prices at the time of this writing are:
- Generator Cover, part # 5LV-15411-00-00, $41.80
- Clutch Cover, part # 5LV-15421-00-00, $86.45
New gaskets must be used whenever removing the covers:
- Generator Cover Gasket, part # 4XV-15451-00-00, $2.85
- Clutch Cover Gasket, part # 4XV-15461-00-00, $4.75
There is no need to drain the oil when removing the covers. Just don't use the side stand or oil will spill out. Place
the bike on the centerstand. Use a 5 mm Allen wrench on all the cover hold down bolts.
Remove Generator Cover:
Loosen the bolts in a criss-cross pattern. All the bolts are the same length.
Watch the two pin dowls used as an alignment guide.
Remove Clutch Cover:
First detach the clutch cable. You may have to loosen the cable at the handlebar end first using the thumbwheel
adjustment. Then loosen the bolts in a criss-cross pattern. Again, watch the two
pin dowls used as an alignment guide. The clutch cable attachment bracket comes off at the top held on with
the two longest bolts. A wire attachment bracket at the bottom held on with the shortest bolt is also removed.
Watch the orientation of this bracket so it can be reinstalled the same way. There is another similar
bracket elsewhere on the engine.
I did not remove the engagement rod from the clutch cover. I asked the shop if they could work around it. When I
picked up the polished parts I was informed that they had removed it then reinstalled it afterwards. The accepted
procedure is to replace the rubber oil seal and the taper-bearing with new ones as
trying to replace the originals is likely to damage them. This was not done but I am probably lucky to not
have had any problems.
Bolts and Gaskets:
When the covers are removed the existing gaskets are destroyed. New gaskets must be used when reinstalling
the covers. A suitable gasket sealant compound must be applied to both sides of the gasket first.
Reinstall Generator Cover:
Install the gasket with sealant applied then replace the cover watching the two pin dowls as alignment guides.
Reinstall the bolts in a criss-cross pattern. Torque them down to 8.7 lb-ft, 12 Nm.
Reinstall Clutch Cover:
Install the gasket with sealant applied then replace the cover using the two pin dowls as alignment guides.
The two marks must be aligned on the clutch engagement rod as the cover is reattached. The pull rod
in the clutch must point to the right so the rod can catch properly. This is tricky and may require several attempts.
Make sure the installation is correct before installing the bolts. Place the clutch cable holder bracket in place
then install the two longest bolts to hold it in. Reinstall the wire holder bracket at the bottom with the shortest
bolt. Then reinstall the remaining bolts in a criss-cross pattern and torque them down to 8.7 lb-ft, 12 Nm.
Reattach the clutch cable and perform a clutch adjustment afterwards.
Installed Photos:
Last Updated: 02-19-2003
Copyright © 2001-03, Patrick Glenn, All Rights Reserved.
Yamaha® and FZ1® are registered trademarks of the Yamaha Motor Corporation.
This site is not affiliated in any way with the Yamaha Motor Corporation.
The information presented here reflects solely my personal experience with my motorcycle and is presented
for entertainment purposes only. No information presented here is to be relied upon for issues of rider safety
nor to replace the services of a qualified service technician.
Any attempts to follow or duplicate any of these procedures are done so completely at your own risk.
By reading the information on this site, you agree to assume complete responsibility for any and all actual
or consequential damages that may arise from any information presented herein.
