Yamaha Wr 450 F Owners Manual
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Page 211
4 - 88 ENGENGINE REMOVAL Drive sprocket 1. Install: Drive sprocket 1 Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 2. Install: Lock washer 1 Nut (drive sprocket) 2 NOTE: Tighten the nut while applying the rear brake. New T R..75 Nm (7.5 m · kg, 54 ft · lb) 3. Bend the lock washer tab to lock the nut. 4. Install: Chain guide Chain cover 1 Screw (chain cover) 2 5. Install: O-ring 1 Dowel pin 2 Oil hose 3 Bolt (oil hose) 4 NOTE: Apply the lithium soap base...
Page 212
4 - 89 ENGCRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal:1 Crankcase separation2 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE SEPARATION Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON” sec- tion. Balancer Refer to “BALANCER” section. Kick axle assembly Refer to “KICK AXLE AND SHIFT SHAFT” section. Segment Stator Refer to “AC MAGNETO AND STARTER CLUTCH” section. 1 Timing...
Page 213
4 - 90 ENGCRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q’ty Remarks 10 Oil strainer 1 11 Oil delivery pipe 2 1 12 Crankshaft 1 Use special tool. Refer to “REMOVAL POINTS”. 2
Page 214
4 - 91 ENGCRANKCASE AND CRANKSHAFT CRANKCASE BEARING Extent of removal:1 Crankcase bearing removal Extent of removal Order Part name Q’ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Shift cam and shift forkRefer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section. 1 Oil seal 3 2 Bearing 10 Refer to “REMOVAL POINTS”. 1
Page 215
4 - 92 ENGCRANKCASE AND CRANKSHAFT REMOVAL POINTS Crankcase 1. Separate: Crankcase (right) Crankcase (left) Separation steps: Remove the crankcase bolts, hose guide and clutch cable holder. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. Remove the crankcase (right). NOTE: Place the crankcase with its left side downward and split it by inserting a screw- driver tip into the splitting slit a in the crankcase. Lift the crankcase (right) horizontally...
Page 216
4 - 93 ENGCRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: Crankshaft 1 Use the crankcase separating tool 2. CAUTION: Do not use a hammer to drive out the crankshaft. Crankshaft bearing 1. Remove: Bearing 1 NOTE: Remove the bearing from the crankcase by pressing its inner race. Do not use the removed bearing. Crankcase separating tool: YU-1135-A/90890-01135 INSPECTION Timing chain and timing chain guide 1. Inspect: Timing chain Cracks/stiff → Replace the timing chain and camshaft sprocket as a set....
Page 217
4 - 94 ENGCRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: Runout limit a Small end free play limit b Connecting rod big end side clearance c Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: YU-3097/90890-01252 Standard Runout limit:0.03 mm (0.0012 in)0.05 mm (0.002 in) Small end free play:0.4 ~ 1.0 mm (0.016 ~ 0.039 in)2.0 mm (0.08 in) Side clearance:0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in)0.50 mm (0.02 in) Crack...
Page 218
4 - 95 ENGCRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankshaft bearing 1. Install: Bearing Bearing stopper Bolt (bearing stopper) Screw (bearing stopper) Screw [bearing stopper (crankshaft)] 1 To crankcase (left and right). NOTE: Install the bearing by pressing its outer race parallel. To prevent the screw [bearing stopper (crankshaft)] from becoming loose, crush the screw head periphery a into the concave b using a punch etc. In so doing, take care not to damage the...
Page 219
4 - 96 ENGCRANKCASE AND CRANKSHAFT NOTE: Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. Before installing the crankshaft, clean the contacting surface of crankcase. CAUTION: Do not use a hammer to drive in the crank- shaft. 2. Check: Shifter operation Transmission operation Unsmooth operation → Repair. 3. Install: Oil strainer 1 Bolt (oil strainer) 2...
Page 220
4 - 97 ENGCRANKCASE AND CRANKSHAFT 5. Install: Dowel pin 1 O-ring 2 Crankcase (right) To crankcase (left). NOTE: Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft ham- mer. When installing the crankcase, the connect- ing rod should be positioned at TDC (top dead center). New 6. Tighten: Hose guide 1 Clutch cable holder 2 Bolt (clutch cable holder) Bolt (crankcase) NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7....