Yamaha F400A 2022 - Removing the Starter Motor; Checking the Starter Motor Pinion; Disassembling the Starter Motor

Starter motor
5-46
Removing the starter motor
Before removing the starter motor, make
sure to disconnect the negative battery ter-
minal.
Checking the starter motor pinion
1. Check:
• Teeth of the pinion
Crack/wear → Replace the pinion.
• Turn the pinion counterclockwise to check
that it operates smoothly and turn it clock-
wise to check that it locks in place.
Not smooth → Replace the pinion.
Disassembling the starter motor
1. Remove:
• Magnet switch assembly
TIP:
Some starter motors do not have a shim.
2. Remove:
•Pinion
• Lever
• Starting motor gear assembly
a. Fix the lever “1” in the pulled-out posi-
tion using the bolt “2”.
Be careful not to break the lever.
b. Place a pipe “1” on the pinion stopper
“2”. Tap the pipe “1” using a plastic
hammer to push down the pinion stop-
per “2”, and then remove the clip “3”.
3. Remove:
• Clutch assembly
•Bracket
a. Remove the cap “1”.
b. Place a pipe “2” on the pinion shaft
stopper “3”. Tap the pipe “2” using a
plastic hammer to push down the pin-
ion shaft stopper “3”, and then remove
the clip “4”.
2
3
4
1
Bolt “2”
M5 × 35 mm
Nut “3”
M5
Washer “4”
Inside diameter = 6.5 mm (0.24 in)
Outside diameter = 16.0 mm (0.63 in)
Pipe “1”
(commercially available)
“a” = 22.0 mm (0.87 in)
“b” = 50.0 mm (1.97 in)
a
b
1
2
2
1
3
4
3
a
b
2
2
1