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Yamaha Manuals
Motorcycle
WR450F(Y) 2009
Owner's service manual
Table Of Contents - Yamaha WR450F(Y) 2009 Owner's Service Manual
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Contents
Table of Contents
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Table of Contents
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Table of Contents
Introduction
6
Manual Information
6
Safety Information
6
Weights Of Machines
7
Manual Format
7
How To Read Descriptions
8
Illustrated Symbols
8
Table Of Contents
9
General Information
10
Description
11
Machine Identification
12
Included Parts
12
Important Information
12
Checking Of Connection
13
Special Tools
14
Control Functions
18
Multi-Function Display
19
Basic Mode
19
Operation Buttons
19
Screen Display
19
Changeover To Basic Mode/Race Mode
20
Race Mode
20
Changing Odometer And Tripmeter
20
Putting Measurement On Standby
20
Resetting Measurement Data
21
Correcting Tripmeter A
21
Function Diagram
22
Starting And Break-In
24
Fuel
24
Handling Note
24
Starting A Cold Engine
24
Break-In Procedures
25
The Engine Fails To Start
25
Torque-Check Points
26
Cleaning And Storage
27
General Specifications
28
Chassis
29
Maintenance Specifications
30
Specifications
32
Engine
35
Electrical
37
Tightening Torques
39
General Torque Specifications
44
Definition Of Units
44
Lubrications Diagram
46
Cable Routing Diagram
48
Periodic Maintenance Chart For The Emission Control System
56
Regular Inspection And Adjustments
56
General Maintenance And Lubrication Chart
57
Maintenance Intervals For Competition Use
58
Pre-Operation Inspection And Maintenance
62
General Inspection And Maintenance
62
Removing The Seat, Fuel Tank And Side Covers
63
Removing The Side Cover
64
Removing The Exhaust Pipe And Silencer
65
Checking The Silencer And Exhaust Pipe
66
Installing The Silencer And Exhaust Pipe
66
Checking The Coolant Level
66
Changing The Coolant
66
Checking The Radiator Cap
67
Checking The Radiator Cap Opening Pressure
67
Checking The Cooling System
67
Adjusting The Clutch Cable Free Play
67
Lubricating The Throttle
68
Adjusting The Hot Starter Lever Free Play
68
Cleaning The Air Filter Element
68
Throttle Grip Free Play Adjustment
68
Checking The Engine Oil Level
69
Changing The Engine Oil
70
Checking The Oil Pressure
70
Adjusting The Pilot Screw
71
Adjusting The Engine Idling Speed
71
Adjusting The Valve Clearance
71
Intake
73
Exhaust
73
Cleaning The Spark Arrester
74
Bleding The Hydraulic Brake System
74
Adjusting The Front Brake
74
Adjusting The Rear Brake
75
Checking And Replacing The Front Brake Pads
75
Brake Lever Position Adjustment
75
Pedal Height Adjustment
75
Checking And Replacing The Rear Brake Pads
76
Checking The Rear Brake Pad Insulator
77
Checking The Brake Fluid Level
77
Checking The Sprocket
77
Checking The Drive Chain
77
Adjusting The Drive Chain Slack
78
Checking The Front Fork
78
Cleaning The Front Fork Oil Seal And Dust Seal
78
Relieving The Front Fork Internal Pressure
79
Adjusting The Front Fork Rebound Damping Force
79
Adjusting The Front Fork Compression Damping Force
79
Adjusting The Rear Shock Absorber Spring Preload
79
Adjusting The Rear Shock Absorber Rebound Damping Force
80
Adjusting The Rear Shock Absorber Low Compression Damping Force
80
Adjusting The Rear Shock Absorber High Compression Damping Force
81
Checking The Tire Pressure
81
Checking And Tightening The Spokes
81
Checking The Wheels
81
Lubrication
83
Checking The Spark Plug
84
Checking The Ignition Timing
84
Checking And Charging The Battery
84
Charging Method Using A Variable Voltage Charger
86
Charging Method Using A Constant Voltage Charger
87
Checking The Fuse
88
Replacing The Headlight Bulbs
88
Adjusting The Headlight Beams
89
Tuning
90
Carburetor Setting
90
Atmospheric Conditions And Carburetor Settings
90
Effect Of Setting Parts In Relation To Throttle Valve Opening
90
Adjusting The Pilot Jet
91
Adjusting The Jet Needle Groove Position
91
Adjusting The Jet Needle
91
Relationship With Throttle Opening
91
Carburetor Setting Parts
92
Examples Of Carburetor Setting Depending On Symptom
93
Selection Of The Secondary Reduction Ratio
94
Drive And Rear Wheel Sprockets Setting Parts
94
Tire Pressure
94
Front Fork Setting
94
Adjusting The Spring Preload
95
Setting Of Spring After Replacement
95
Front Fork Setting Parts
95
Rear Suspension Setting
95
Choosing Set Length
96
Rear Shock Absorber Setting Parts
96
Suspension Setting (Front Fork)
97
Suspension Setting (Rear Shock Absorber)
98
Radiator
99
Removing The Radiator
99
Checking The Radiator
101
Installing The Radiator
101
Carburetor
102
Removing The Carburetor
102
Disassembling The Carburetor
104
Removing The Pilot Screw
106
Checking The Carburetor
106
Checking The Needle Valve
106
Checking The Throttle Valve
106
Checking The Float
107
Checking The Starter Plunger
107
Checking The Accelerator Pump
107
Checking The Air Cut Valve
107
Adjusting The Accelerator Pump Timing
109
Installing The Carburetor
109
Air Induction System
111
Removing The Air Induction System
111
Checking The Air Induction System
112
Camshafts
113
Removing The Cylinder Head Cover
113
Removing The Camshafts
114
Checking The Camshaft
115
Checking The Camshaft Sprocket
116
Checking The Decompression System
116
Checking The Timing Chain Tensioner
116
Installing The Camshaft
117
Cylinder Head
118
Removing The Cylinder Head
118
Checking The Cylinder Head
119
Installing The Cylinder Head
119
Warpage Measurement And Resurfacing
119
Valves And Valve Springs
121
Removing The Valves And Valve Springs
121
Removing The Valve Lifter And Valve Cotter
122
Checking The Valve
122
Checking The Valve Springs
124
Checking The Valve Lifters
124
Installing The Valves
124
Cylinder And Piston
125
Removing The Cylinder And Piston
125
Removing The Piston And Piston Ring
126
Checking The Cylinder And Piston
126
Checking The Piston Ring
126
Checking The Piston Pin
127
Installing The Piston Ring And Piston
127
Installing The Cylinder
127
Clutch
128
Removing The Clutch
128
Removing The Clutch Boss
130
Checking The Clutch Housing And Boss
130
Checking The Primary Driven Gear
130
Checking The Clutch Springs
130
Oil Filter Element And Water Pump
132
Removing The Oil Filter Element And Water Pump
132
Removing The Impeller Shaft
134
Removing The Oil Seal
134
Checking The Impeller Shaft
134
Checking The Bearing
134
Installing The Kickstarter Crank
135
Installing The Water Pump Housing
135
Installing The Water Filter Element
135
Balancer
136
Removing The Balancer
136
Checking The Primary Drive Gear, Balancer Shaft Drive Gear
137
Checking The Balancer Shaft Driven Gear
137
Checking The Balancer
137
Installing The Balancer
137
Oil Pump
138
Removing The Oil Pump
138
Checking The Oil Pump
140
Installing The Oil Pump
140
Kick Shaft And Shift Shaft
141
Removing The Kick Shaft And Shift Shaft
141
Removing The Kick Shaft Assembly
143
Removing The Shift Guide And Shift Lever Assembly
143
Removing The Segment
143
Checking The Kick Shaft And Ratchet Wheel
143
Installing The Shift Guide And Shift Lever Assembly
144
Installing The Kick Idle
144
Installing The Shift Shaft
144
Installing The Kick Shaft Assembly
144
Ac Magneto And Starter Clutch
146
Removing The Ac Magneto And Starter Clutch
146
Removing The Rotor
148
Removing The Starter Clutch
148
Checking The Ac Magneto
148
Checking The Woodruff Key
148
Engine Removal
151
Removing The Drive Sprocket
153
Removing The Engine
153
Installing The Engine
153
Installing The Brake Pedal
153
Installing The Neutral Switch
154
Crankcase And Crankshaft
155
Removing The Crankshaft
155
Removing The Crankcase Bearing
157
Disassembling The Crankcase
158
Removing The Balancer Shaft
158
Checking The Timing Chain And Timing Chain Guide
158
Checking The Crankcase
158
Checking The Crankshaft
159
Checking The Oil Strainer
159
Installing The Crankcase Bearing
159
Installing The Crankshaft
159
Transmission, Shift Cam And Shift Fork
161
Removing The Transmission, Shift Cam And Shift Fork
161
Removing The Transmission
162
Checking The Gears
162
Checking The Shift Fork, Shift Cam And Segment
162
Installing The Transmission
162
Front Wheel And Rear Wheel
164
Removing The Front Wheel
164
Removing The Rear Wheel
165
Removing The Wheel Bearing
166
Checking The Wheel
166
Checking The Wheel Axle
166
Checking The Brake Disc
166
Installing The Rear Wheel
167
Removing The Front Brake
169
Front Brake And Rear Brake
169
Removing The Rear Brake
170
Disassembling The Brake Caliper
171
Disassembling The Brake Master Cylinder
172
Draining The Brake Fluid
173
Removing The Brake Caliper Piston
173
Removing The Brake Caliper Piston Seal Kit
173
Checking The Brake Master Cylinder
173
Checking The Brake Caliper
174
Checking The Brake Hose
174
Installing The Brake Caliper Piston
174
Installing The Front Brake Caliper
174
Installing The Rear Brake Caliper
175
Installing The Brake Master Cylinder Kit
175
Installing The Front Brake Master Cylinder
176
Installing The Rear Brake Master Cylinder
176
Installing The Front Brake Hose
176
Installing The Rear Brake Hose
177
Filling The Brake Fluid
177
Front Fork
179
Removing The Front Fork
179
Disassembling The Front Fork
180
Removing The Front Fork Cap Bolt
181
Removing The Inner Tube
181
Removing The Damper Rod
181
Checking The Damper Rod
181
Checking The Outer Tube
182
Checking The Front Fork Cap Bolt
182
Assembling The Front Fork
182
Installing The Front Fork
185
Handlebar
186
Removing The Handlebar
186
Removing The Brake Master Cylinder
187
Removing The Grip
187
Checking The Handlebar
187
Installing The Handlebar
187
Steering
190
Removing The Steering
190
Removing The Steering Ring Nut
192
Removing The Lower Bearing
192
Removing The Bearing Race
192
Checking The Bearing And Bearing Race
192
Swingarm
194
Removing The Swingarm
194
Disassembling The Swingarm
195
Removing The Cap
196
Removing The Bearing
196
Checking The Swingarm
196
Installing The Bearing And Oil Seal
196
Rear Shock Absorber
199
Removing The Rear Shock Absorber
199
Notes On Disposal
201
Checking The Rear Shock Absorber
201
Installing The Bearing
201
Installing The Spring (Rear Shock Absorber)
202
Installing The Rear Shock Absorber
202
Elwctrical Components And Wiring Diagram
205
Electrical Components And Wiring Diagram
206
Ignition System
207
Inspection Steps
207
Spark Gap Test
208
Checking The Couplers, Leads And Ignition Coil Connection
208
Checking The Engine Stop Switch
208
Checking The Main Switch
208
Electric Starting System
209
Checking The Neutral Switch
209
Starting Circuit Cut-Off System Operation
209
Checking The Starter Motor Operation
211
Checking The Starting Circuit Cut-Off Relay
211
Checking The Starter Relay
211
Checking The Clutch Switch
211
Checking The Start Switch
212
Removing The Starter Motor
213
Disassemling The Starter Motor
214
Chexking And Repairing The Starter Motor
215
Assembling The Starter Motor
215
Charging System
217
Checking The Couplers And Leads Connection
218
Throttle Position Sensor System
219
Checking The Throttle Position Sensor Coil
220
Changing And Adjusting The Throttle Position Sensor
220
Checking The Throttle Position Sensor Input Voltage
221
Lighting System
222
Checking The Taillight
223
Checking The Rectifier/Regulator
223
Signaling System
224
Checking The Multi-Function Display Input Voltage
225
Checking The Multi-Function Display Output Voltage
225
Checking The Speed Sensor Output Voltage
225
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Table of Contents
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