Yamaha Wr 450 F Owners Manual
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Page 301
–+ELEC 6 - 8 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. *3 marked: Refer to “MAIN SWITCH INSPECTION” section. *4 marked: Refer to “NEUTRAL SWITCH INSPECTION” section. NOTE: Remove the following parts before inspection. 1) Seat 2) Rear fender Use 12 V battery in this inspection. Use the...
Page 302
6 - 9 –+ELECELECTRIC STARTING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. STARTER MOTOR OPERATION 1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3. Not operate → Repair or replace the starter motor. WARNING A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn....
Page 303
6 - 10 –+ELECELECTRIC STARTING SYSTEM STARTER RELAY INSPECTION 1. Remove: Starter relay 2. Inspect: Starter relay conduct Use 12 V battery. Continuous while not connected to the battery → Replace. Not continuous while connected to the battery → Replace.Battery (+) lead → Starter relay terminal 1 Battery (–) lead → Starter relay terminal 2 Tester (+) lead → Starter relay terminal 3 Tester (–) lead → Starter relay terminal 4 Ter- minal 3 Ter- minal 4Tester selec- tor position Connected to battery Ω...
Page 304
6 - 11 –+ELECELECTRIC STARTING SYSTEM DIODE INSPECTION 1. Remove the diode from wire harness. 2. Inspect: Diode continuity Use pocket tester (tester selection posi- tion Ω × 1) Incorrect continuity → Replace. Tester (+) → Blue/Red terminal 1 Tester (–) → Sky blue terminal 2Continuous Tester (+) → Blue/Red terminal 1 Tester (–) → Blue/Yellow terminal 3Continuous Tester (+) → Sky blue terminal 2 Tester (–) → Blue/Red terminal 1No continuous Tester (+) → Blue/Yellow terminal 3 Tester (–) →...
Page 305
6 - 12 –+ELECELECTRIC STARTING SYSTEM STARTER MOTOR 0 9 56 7 5 0 8 9 4 3 2 1 New New New B 5 1 Extent of removal:1 Starter motor disassembly Extent of removal Order Part name Q’ty Remarks STARTER MOTOR REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Crankcase cover (left) Refer to “AC MAGNETO AND STARTER CLUTCH” section in the CHAPTER 4. 1 Starter motor 1 STARTER MOTOR DISASSEM- BLY 1Starter motor front cover 1 2Washer (starter motor...
Page 306
6 - 13 –+ELECELECTRIC STARTING SYSTEM 0 9 56 7 5 0 8 9 4 3 2 1 New New New B 5 1 Extent of removal Order Part name Q’ty Remarks 6Starter motor yoke 1 7Armature assembly 1 8Starter motor rear cover 1 9Brush 2 0Brush spring 2 1
Page 307
6 - 14 –+ELECELECTRIC STARTING SYSTEM INSPECTION AND REPAIR 1. Check: Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: Commutator diameter a Out of specification → Replace the starter motor. 3. Measure: Mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. NOTE: The mica must be undercut to ensure proper operation of the commutator. Min. commutator diameter 16.6 mm (0.65 in) Mica undercut...
Page 308
6 - 15 –+ELECELECTRIC STARTING SYSTEM 5. Measure: Brush length a Out of specification → Replace the brushes as a set. Min. brush length 3.5 mm (0.14 in) 6. Measure: Brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 3.92 ~ 5.88 N (400 ~ 600 gf, 14.1 ~ 21.2 oz) ASSEMBLY 1. Install: Brush spring 1 Brush 2 2. Install: Armature assembly 1 Install while holding down the brush using a thin screw driver. CAUTION: Be careful not to damage the brush during...
Page 309
6 - 16 –+ELECELECTRIC STARTING SYSTEM 3. Install: O-ring 1 Starter motor yoke 2 NOTE: Align the match mark a on the starter motor yoke with the match mark b on the starter motor rear cover. Install the starter motor yoke with its groove c facing rear cover. a b c 2 1 NewNew 4. Install: O-ring 1 Circlip Plain washer 2 Washer (starter motor front cover) 3 Starter motor front cover 4 NOTE: For installation, align the projections on the washer with the slots in the front cover. Align the...
Page 310
–+ELEC 6 - 17 CHARGING SYSTEM EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. NOTE: Remove the following parts before inspection. 1) Seat 2) Fuel tank Use the following special tool in this inspection. Pocket tester: YU-3112-C/90890-03112Inductive tachometer: YU-8036-B Engine tachometer:...