Now is a good time to clean the gasket surfaces of old gasket remnants. Do this for the gasket surface of the engine case, as well as the generator cover. Be sure to wipe up any particles that may fall in.

Next mount the starter-clutch gear on to the rotor, if it came off. It just presses on. See photo below to see what they look like when separated.

Next, apply either retaining compound or red thread-lock to the following (Note: see Parts section above, for details on this):

• The tapered (lapped) section of the generator shaft
• The rotor taper-hole

Now, apply red thread-lock to the following:

• The shaft end-bolt
• The shaft threaded hole

Be careful to immediately and thoroughly wipe off any liquid that spills on any other areas. Then slide the rotor assembly on to its shaft, and thread the end-bolt and washer on.

Bolt and torque the shaft end-bolt to at least 115 ft-lbs. You can stabilize the generator shaft using any of the following methods:

• Put the transmission in gear. Tip: Be sure you prevent your bike from rolling as you torque the rotor onto the shaft. For instance, you could have someone stabilize the bike for you while you tighten the bolt.
• Use a Yamaha generator rotor holder tool (sheave holder).
• Use an adjustable, open-end (crescent type) wrench on the rotor to counter much of torque.
• Use an impact wrench, as long as you can set it, and your compressor, to at least 115 ft-lbs of torque.

Now install the starter-clutch gear-train. See photo below.

If you separated the oil delivery pipe from the generator cover, bolt them back together now. Torque the bolts to 7.2 ft-lbs, which is 86.4 in-lbs. Be sure both ends of the oil delivery pipe have their O-rings installed beforehand.

Insert the generator cover's two alignment dowels back into the engine case. Then slip a new generator cover gasket over the dowels.

Tip: The generator cover is magnetized to the rotor. As soon as you begin installing the cover, it will be sucked in by magnetic force.

Bolt and torque the generator cover. Be sure to use a criss-cross bolt tightening pattern, tightening bolts evenly, just a little at a time. Torque the bolts to 7.2 ft-lbs. Remember, the two long bolts are the only ones that are not perimeter bolts.

Tip: The long bolt near the bottom of the cover has a copper or aluminum washer. I recommend you install a new washer at this point. I did not, and it leaked.

Bolt the oil-delivery-pipe back into its hole in the right-side of the engine case, using 7.2 ft-lbs of torque.