Yamaha Wr 450 F Owners Manual
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SPEC 2 - 14 MAINTENANCE SPECIFICATIONS Wheel: Front wheel type Spoke wheel ---- Rear wheel type Spoke wheel ---- Front rim size/material 21 × 1.60/Aluminum ---- Rear rim size/material 18 × 2.15/Aluminum ---- Rim runout limit: Radial ---- 2.0 mm (0.08 in) Lateral ---- 2.0 mm (0.08 in) Drive chain: Type/manufacturer DID520VM/DAIDO ---- Number of links 113 links + joint ---- Chain slack 40 ~ 50 mm (1.6 ~ 2.0 in) ---- Chain length (10 links) ----150.1 mm (5.91 in) Front disc brake: Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in)250 × 2.5 mm (9.84 × 0.10 in) Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04 in) Master cylinder inside dia. 11.0 mm (0.433 in) ---- Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ---- Brake fluid type DOT #4 ---- Rear disc brake: Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in)245 × 3.5 mm (9.65 × 0.14 in) Deflection limit ----0.15 mm (0.006 in) Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04 in) Master cylinder inside dia. 11.0 mm (0.433 in) ---- Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ---- Brake fluid type DOT #4 ---- Brake lever and brake pedal: Brake lever position 95 mm (3.74 in) ---- Brake pedal height (vertical height above footrest top)5 mm (0.20 in) ---- Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ---- Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit
SPEC 2 - 15 MAINTENANCE SPECIFICATIONS NOTE: 1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench, then loosen the ring nut one turn. 2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb). Part to be tightened Thread size Q’tyTightening torque Nm m·kg ft·lb Handle crown and outer tube M8 × 1.25 4 23 2.3 17 Under bracket and outer tube M8 × 1.25 4 20 2.0 14 Handle crown and steering shaft M24 × 1.0 1 145 14.5 105 Handlebar holder (upper) M8 × 1.25 4 28 2.8 20 Steering ring nut M28 × 1.0 1 Refer to NOTE. Front fork and cap bolt M48 × 1.0 2 30 3.0 22 Front fork and base valve M30 × 1.0 2 55 5.5 40 Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21 Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7 Front fork and protector M6 × 1.0 6 10 1.0 7.2 Front fork and brake hose holder M6 × 1.0 2 10 1.0 7.2 Front fork and hose cover M8 × 1.25 1 16 1.6 11 Front fork and hose cover M6 × 1.0 1 7 0.7 5.1 Throttle cable cap M5 × 0.8 2 4 0.4 2.9 Clutch lever holder mounting M5 × 0.8 2 4 0.4 2.9 Hot starter lever holder mounting M5 × 0.8 2 4 0.4 2.9 Hot starter lever mounting M5 × 0.8 1 2 0.2 1.4 Lights switch M4 × 0.7 2 2 0.2 1.4 Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5 Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4 Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3 Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3 Brake lever position locknut M6 × 1.0 1 5 0.5 3.6 Hose guide (front brake hose) M5 × 0.8 2 4 0.4 2.9 Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22 Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22 Front brake caliper and front fork M8 × 1.25 2 23 2.3 17 Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2 Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13 Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3 Front wheel axle and nut M16 × 1.5 1 105 10.5 75 Front wheel axle holder M8 × 1.25 4 23 2.3 17 Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7 Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10 Brake pedal mounting M8 × 1.25 1 26 2.6 19 Rear brake master cylinder and frame M6 × 1.0 2 11 1.1 8.0 Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4 Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22 Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
SPEC 2 - 16 MAINTENANCE SPECIFICATIONS Part to be tightened Thread size Q’tyTightening torque Nm m·kg ft·lb Rear wheel axle and nut M20 × 1.5 1 125 12.5 90 Driven sprocket and wheel hub M8 × 1.25 6 50 5.0 36 Nipple (spoke)–72 3 0.3 2.2 Disc cover and rear brake caliper M6 × 1.0 2 7 0.7 5.1 Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1 Chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11 Engine mounting: Engine upper bracket and frame M10 × 1.25 2 55 5.5 40 Engine lower bracket and frame M8 × 1.25 4 34 3.4 24 Engine and frame (front) M10 × 1.25 1 69 6.9 50 Engine and frame (upper) M10 × 1.25 1 55 5.5 40 Engine and frame (lower) M10 × 1.25 1 69 6.9 50 Engine guard (left and right) M8 × 1.25 2 23 2.3 17 Engine skid plate mounting M6 × 1.0 6 10 1.0 7.2 Regulator bracket mounting M6 × 1.0 2 7 0.7 5.1 Regulator mounting M6 × 1.0 2 7 0.7 5.1 Pivot shaft and nut M16 × 1.5 1 85 8.5 61 Relay arm and swingarm M14 × 1.5 1 80 8.0 58 Relay arm and connecting rod M14 × 1.5 1 80 8.0 58 Connecting rod and frame M14 × 1.5 1 80 8.0 58 Rear shock absorber and frame M10 × 1.25 1 56 5.6 40 Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38 Rear frame and frame (upper) M8 × 1.25 1 32 3.2 23 Rear frame and frame (lower) M8 × 1.25 2 29 2.9 21 Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7 Swingarm and patch M4 × 0.7 4 2 0.2 1.4 Drive chain tensioner mounting (upper) M8 × 1.25 1 19 1.9 13 Drive chain tensioner mounting (lower) M8 × 1.25 1 20 2.0 14 Chain support and swingarm M6 × 1.0 3 7 0.7 5.1 Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3 Fuel tank mounting M6 × 1.0 2 10 1.0 7.2 Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1 Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1 Fuel tank and hooking screw (fitting band) M6 × 1.0 1 7 0.7 5.1 Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1 Seat mounting M8 × 1.25 2 23 2.3 17 Side cover mounting M6 × 1.0 2 7 0.7 5.1 Air scoop and fuel tank M6 × 1.0 6 4 0.4 2.9 Air scoop and radiator panel (lower) M6 × 1.0 2 4 0.4 2.9 Front fender mounting M6 × 1.0 4 7 0.7 5.1 Rear fender mounting (front) M6 × 1.0 2 7 0.7 5.1 Rear fender mounting (rear) M6 × 1.0 2 10 1.0 7.2 Trip meter mounting M6 × 1.0 2 7 0.7 5.1
SPEC 2 - 17 MAINTENANCE SPECIFICATIONS NOTE: - marked portion shall be checked for torque tightening after break-in or before each race. Meter cable holder and protector M5 × 0.8 2 4 0.4 2.9 Headlight stay (lower) and under bracket M8 × 1.25 2 7 0.7 5.1 Headlight body and headlight unit M6 × 1.0 2 7 0.7 5.1 Headlight mounting (left and right) M6 × 1.0 2 10 1.0 7.2 Headlight mounting (lower) M6 × 1.0 1 7 0.7 5.1 Taillight mounting M6 × 1.0 3 4 0.4 2.9 Taillight lead clamp and rear fender M4 × 1.59 2 0.5 0.05 0.36 Coolant reservoir tank mounting M6 × 1.0 2 7 0.7 5.1 Sidestand bracket mounting M10 × 1.25 2 66 6.6 48 Sidestand mounting M10 × 1.25 1 64 6.4 46 Part to be tightened Thread size Q’tyTightening torque Nm m·kg ft·lb
SPEC 2 - 18 MAINTENANCE SPECIFICATIONS EC212300 ELECTRICAL Item Standard Limit Ignition system: Advancer type Electrical ---- C.D.I.: Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F) (White – Red)---- CDI unit-model/manufacturer 5TJ-00/YAMAHA (For USA) 5TJ-10/YAMAHA (Except for USA)---- ---- Ignition coil: Model/manufacturer 5TA-00/DENSO ---- Minimum spark gap 6 mm (0.24 in) ---- Primary winding resistance 0.08 ~ 0.10 Ω at 20 ˚C (68 ˚F) ---- Secondary winding resistance 4.6 ~ 6.8 kΩ at 20 ˚C (68 ˚F) ---- Charging system: System type AC magneto ---- Model/manufacturer 5TJ-00/YAMAHA ---- Normal output 14 V/120 W at 5,000 r/min ---- Charging coil resistance (color) 0.288 ~ 0.432 Ω at 20 ˚C (68 ˚F) (White – Ground)---- Lighting coil resistance (color) 0.224 ~ 0.336 Ω at 20 ˚C (68 ˚F) (Yellow – Ground)---- Rectifier/regulator: Regulator type Semiconductor short circuit ---- Model/manufacture SH712AA/SHINDENGEN ---- Regulated voltage (AC) 13.0 ~ 14.0 V ---- Regulated voltage (DC) 14.1 ~ 14.9 V ---- Rectifier capacity (AC) 12 A ---- Rectifier capacity (DC) 8 A ---- Electric starting system: Type Constant mesh ---- Starter motor: Model/manufacturer 5TJ00/YAMAHA ---- Operation voltage 12 V ---- Output 0.48 kW ---- Armature coil resistance 0.0117 ~ 0.0143 Ω at 20 ˚C (68 ˚F)---- Brush overall length 7 mm (0.28 in) 3.5 mm (0.14 in) Brash quantity 2 pcs. ---- Spring force 3.92 ~ 5.88 N (400 ~ 600 g, 14.1 ~ 21.2 oz)---- Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65 in) Mica undercut (depth) 1.5 mm (0.06 in) ----
SPEC 2 - 19 MAINTENANCE SPECIFICATIONS NOTE: Tighten the rotor nut to 65 Nm (6.5 m·kg, 47 ft·lb), loosen and retighten the rotor nut to 65 Nm (6.5 m·kg, 47 ft·lb). Starter relay: Model/manufacturer 2768090-A/JIDECO ---- Amperage rating 180 A ---- Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ---- Starting circuit cut-off relay: Model/manufacturer ACM33221 M06/MATSUSHITA ---- Coil winding resistance 75.69 ~ 92.51 Ω at 20 ˚C (68 ˚F) ---- Fuse (amperage × quantity): Main fuse 10 A × 1 ---- Reserve fuse 10 A × 1 ---- Part to be tightened Thread size Q’tyTightening torque Nm m·kg ft·lb Stator M5 × 0.8 2 7 0.7 5.1 Holder (AC magneto lead) M5 × 0.8 2 7 0.7 5.1 Rotor M12 × 1.25 1 Refer to NOTE. Neutral switch M5 × 0.8 2 4 0.4 2.9 Starter motor M6 × 1.0 2 10 1.0 7.2 Starter relay terminal M6 × 1.0 2 4 0.4 2.9 Item Standard Limit
2 - 20 SPEC GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Com- ponents should be at room temperature. A: Distance between flats B: Outside thread diameter EC230000 DEFINITION OF UNITS A (Nut)B (Bolt)TORQUE SPECIFICATION Nm m•kg ft•lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm6 mm 8 mm 10 mm 12 mm 14 mm 16 mm6 15 30 55 85 1300.6 1.5 3.0 5.5 8.5 134.3 11 22 40 61 94 Unit Read Definition Measure mm cmmillimeter centimeter10 -3 meter 10 -2 meterLength Length kg kilogram 10 3 gram Weight N Newton 1 kg × m/sec 2 Force Nm m • kgNewton meter Meter kilogramN × m m × kgTorque Torque Pa Pascal N/m 2 Pressure N/mm Newton per millimeter N/mm Spring rate L cm 3 Liter Cubic centimeter— —Volume or capacity Volume or capacity r/min Revolution per minute—Engine speed
2 - 21 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 Intake camshaft 3 Exhaust camshaft 4 Oil cleaner element 5 Oil pump 6 Main axle 7 Drive axle 7 6 543 2 14 5 A - A D - D G G D D A A
2 - 22 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Connecting rod 3 Oil cleaner element 4 Crankshaft 5 Main axle 6 Drive axle 7 Oil delivery pipe 1 2 3 4 5 67
2 - 23 SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose 2 Clamp 3 Diode 4 Wire harness 5 Hot starter cable 6 Negative battery lead 7 Starter motor lead 8 TPS (throttle position sen- sor) lead 9 Neutral switch lead 0 Oil hose A Hose holder B Radiator hose 4 C Cylinder head breather hose D AC magneto lead E Radiator hose 1 F Oil tank breather hose G Lights switch lead H Brake hose I Hose guide J Carburetor breather hose K Overflow hose L Coolant reservoir tank breather hose Å Insert the fuel tank breather hose into the hole in the steering shaft cap. ıFasten the diode of the wire har- ness and rectifier/regulator lead (at its protecting tube) to the frame at the white tape for the diode with a plastic locking tie and cut off the tie end.ÇFasten the wire harness, recti- fier/regulator lead, coolant res- ervoir hose and hot starter cable to the frame with a plastic lock- ing tie and cut off the tie end. ÎFasten the wire harness, recti- fier/regulator lead and coolant reservoir hose to the frame with a plastic locking tie and cut off the tie end. ‰Fasten the wire harness to the frame at its white tape with a plastic locking tie and cut off the tie end.