Yamaha Wr 450 F Owners Manual
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ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning Illustrated symbols 8 to D are used to identify the specifications appearing in the text. 8 With engine mounted 9 Special tool 0 Filling fluid A Lubricant B Tightening C Specified value, Service limit D Resistance ( Ω ), Voltage (V), Electric current (A) Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca- tion of lubrication point. E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease Illustrated symbols I to J in the exploded diagrams indicate where to apply a locking agent and where to install new parts. I Apply locking agent (LOCTITE ® ) JUse new one 12 34 56 78 90 AB CD EF GH IJ GEN INFOSPEC INSP ADJENG CHAS–+ELEC TUN T R.. EM BM New
EC090000 INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 TUNING TUN 7 GEN INFO INSP ADJ –+
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......................................... 1-1 MACHINE IDENTIFICATION .................... 1-2 IMPORTANT INFORMATION ................... 1-3 CHECKING OF CONNECTION ................. 1-6 SPECIAL TOOLS ...................................... 1-7 CONTROL FUNCTIONS ......................... 1-10 FUEL ....................................................... 1-14 STARTING AND BREAK-IN ................... 1-15 TORQUE-CHECK POINTS ..................... 1-19 CLEANING AND STORAGE ................... 1-20 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS .................. 2-1 MAINTENANCE SPECIFICATIONS ......... 2-4 GENERAL TORQUE SPECIFICATIONS ................................... 2-20 DEFINITION OF UNITS ........................... 2-20 LUBRICATION DIAGRAMS .................... 2-21 CABLE ROUTING DIAGRAM ................. 2-23 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS ................... 3-1 PRE-OPERATION INSPECTION AND MAINTENANCE ................................ 3-4 ENGINE ..................................................... 3-5 CHASSIS ................................................. 3-26 ELECTRICAL .......................................... 3-48
CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ................................. 4-1 EXHAUST PIPE AND SILENCER ............ 4-3 RADIATOR ................................................ 4-5 CARBURETOR ......................................... 4-8 CAMSHAFTS .......................................... 4-21 CYLINDER HEAD ................................... 4-29 VALVES AND VALVE SPRINGS ........... 4-33 CYLINDER AND PISTON ....................... 4-42 CLUTCH .................................................. 4-48 OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ..... 4-55 BALANCER ............................................. 4-62 OIL PUMP ............................................... 4-65 KICK AXLE AND SHIFT SHAFT ............ 4-69 AC MAGNETO AND STARTER CLUTCH ....................... 4-76 ENGINE REMOVAL ................................ 4-83 CRANKCASE AND CRANKSHAFT ....... 4-89 TRANSMISSION, SHIFT CAM AND SHIFT FORK .................................. 4-98 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL ....... 5-1 FRONT BRAKE AND REAR BRAKE ..... 5-11 FRONT FORK ......................................... 5-27 HANDLEBAR .......................................... 5-40 STEERING .............................................. 5-46 SWINGARM ............................................ 5-52 REAR SHOCK ABSORBER ................... 5-60
CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........................... 6-1 MAP-CONTROLLED CDI UNIT ................ 6-2 IGNITION SYSTEM ................................... 6-3 ELECTRIC STARTING SYSTEM .............. 6-7 CHARGING SYSTEM ............................. 6-17 TPS (THROTTLE POSITION SENSOR) SYSTEM .................................................. 6-19 LIGHTING SYSTEM ................................ 6-24 CHAPTER 7 TUNING ENGINE ..................................................... 7-1 CHASSIS ................................................. 7-10
GEN INFO 1 - 1 DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever 2 Hot starter lever 3 “ENGINE STOP” button 4 Trip meter 5 Main switch 6 Lights switch 7 Start switch 8 Front brake lever 9 Throttle grip 0 Radiator cap A Fuel tank cap B Taillight C Kickstarter D Fuel tank E Headlight F Radiator G Coolant drain bolt H Rear brake pedal I Valve joint J Fuel cock K Cold starter knob L Air cleaner M Drive chain N Shift pedal O Oil dipstick P Front fork NOTE: The machine you have purchased may differ slightly from those shown in the following. Designs and specifications are subject to change without notice. B CDE F G H 1234 5 6 7 8 9 0 A IJ K L M N O P 1
1 - 2 GEN INFO MACHINE IDENTIFICATION EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for posi- tive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine. EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe. 1 EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right-side of the engine. 1 EC124000 MODEL LABEL The model label 1 is affixed to the frame under the rider’s seat. This information will be needed to order spare parts. 1
1 - 3 GEN INFO IMPORTANT INFORMATION EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts as fol- lows. Silencer exhaust port Side cover air intake port Water pump housing hole at the bottom Drain hole on the cylinder head (right side) All electrical components 2. Use proper tools and cleaning equip- ment. Refer to “SPECIAL TOOLS” sec- tion. 3. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire.
1 - 4 GEN INFO IMPORTANT INFORMATION EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is over- hauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. EC134000 LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. EC135001 BEARINGS AND OIL SEALS 1. Install the bearing(s) 1 and oil seal(s) 2 with their manufacturer’s marks or num- bers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light- weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. CAUTION: Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.