Table Of Contents - Yamaha WR450F(W) Owner's Service Manual

Table of Contents

Important Notice6
Fim Machine Weights. Weights Of Machines Without Fuel10
How To Use The Manual12
Description12
Renseignements Generaux13
Manual Format14
How To Read Descriptions14
Illustrated Symbols16
Table Of Contents20
General Information26
Allgemeine Angaben27
Machine Identification28
The Vehicle Identification Number28
The Engine Serial Number28
The Model Label28
Identification De La Moto29
Preparation For Removal And Disassembly30
Important Information30
Informations Importantes31
Wichtige Informationen31
All Replacement Parts32
Gaskets, Oil Seals And O-Rings32
Lock Washers/Plates And Cotter Pins32
Bearings And Oil Seals32
Circlips34
Checking Of Connection36
Verification Des Connexions37
Special Tools38
Outils Speciaux41
Herramientas Especiales47
Control Functions50
Main Switch50
Main Switch Indicator Light50
"Engine Stop" Button50
Fonctions Des Commandes51
Engine51
Moteur51
Motor51
Clutch Lever52
Shift Pedal52
Kickstarter52
Throttle Grip, Front Brake Lever52
Bedienungselemente Und Deren Funktion53
Funciones De Los Mandos53
Rear Brake Pedal54
Fuel Cock54
Cold Starter Knob54
Hot Starter Lever54
Sidestand56
Valve Joint56
Spark Plug Wrench56
Nipple Wrench, Jet Needle Pull-Up Tool56
Multi-Function Display58
Ecran Multifonction59
Multi-Function Display Basic Mode60
Changing Speedometer Display (For U.k.)60
Setting The Time60
Mode De Base61
Réglage de L'heure61
Normal-Betriebsart61
Uhr Stellen61
Función Básica61
Ajuste De La Hora61
Changing Odometer And Tripmeter A/B (Trip A/B)62
Changeover To Basic Mode/Race Mode62
Changeover From Basic Mode To Race Mode62
Returning To Basic Mode From Race Mode64
Race Mode64
Putting Measurement On Standby64
Manual Start64
Auto Start66
Resetting Measurement Data68
Resetting Tripmeter A (Trip A)68
Resetting Tripmeter A (Trip A) And Timer68
Correcting Tripmeter A (Trip A)68
Function Diagram70
Fuel72
Carburant73
Starting And Break-In74
Air Filter Maintenance74
Starting A Cold Engine74
Puesta En Marcha Y Rodaje75
Mise En Marche Et Rodage75
Starten Und Einfahren75
Starting A Warm Engine78
Restarting An Engine After A Fall78
The Engine Fails To Start78
Break-In Procedures80
Torque-Check Points80
Points De Verification Des Couples De Serrage83
Anzugsdrehmomente Kontrollieren84
Cleaning And Storage86
Limpieza Y Almacenamiento87
Nettoyage Et Remisage87
Pflege Und Lagerung87
Storage88
General Specifications90
Chassis91
Maintenance Specifications - Engine93
Lubrication Chart99
Maintenance Specifications - Chassis102
Maintenance Specifications - Electrical107
General Torque Specifications109
Definition Of Units109
Caracteristiques Generales110
Caracteristiques D'entretien113
Caracteristiques Generales De Couple129
Definition Des Unites129
Allgemeine Technische Daten130
Fahrwerk131
Allgemeine Anzugsmomente149
Masseinheiten149
Especificaciones Generales150
Especificaciones De Mantenimiento153
Especificaciones Generales De Apriete169
Lubrication Diagrams170
Schmiersystem171
Schaubilder171
Diagrammes De Lubrification173
Cable Routing Diagram174
Kabelführungs-Schaubild175
De Cheminement Des Cables175
Diagrama De Cableado175
Regular Inspection And Adjustments192
Maintenance Intervals192
Regelmässige Wartungs- Und Einstellarbeiten198
Wartungsintervalle198
Intervalos De Mantenimiento201
Pre-Operation Inspection And Maintenance204
General Inspection And Maintenance204
Routinekontrolle Vor Fahrtbeginn206
Revisión Previay Mantenimiento207
Engine/Coolant Level Inspection/Coolant Replacement208
Coolant Level Inspection208
Coolant Replacement208
Radiator Cap Inspection214
Radiator Cap Opening Pressure Inspection214
Radiateur215
Cooling System Inspection216
Clutch Adjustment216
Embrayage217
Throttle Cable Adjustment218
Throttle Grip Free Play Adjustment Steps218
Throttle Lubrication220
Hot Starter Lever Adjustment220
Air Filter Cleaning222
Engine Oil Level Inspection226
Recommended Oil228
Engine Oil Replacement230
Cambio De Aceite Del Motor231
Oil Filter Replacement Steps232
Filtre A Huile, Pompe233
Idle Speed Adjustment234
Valve Clearance Adjustment236
And Side Covers236
Valve Clearance Adjustment Steps238
Intake244
Exhaust244
Spark Arrester Cleaning (For Usa)248
Arriere249
Brake System Air Bleeding250
Chasis251
Front Brake Adjustment252
Rear Brake Adjustment254
Front Brake Pad Inspection And Replacement254
Fourche257
Rear Brake Pad Inspection And Replacement258
Rear Brake Pad Insulator Inspection262
Brake Fluid Level Inspection262
Sprockets Inspection264
Drive Chain Inspection264
Drive Chain Slack Adjustment268
Front Fork Inspection270
Front Fork Oil Seal And Dust Seal Cleaning270
Front Fork Internal Pressure Relieving272
Front Fork Rebound Damping Force Adjustment272
Front Fork Compression Damping Force Adjustment274
Rear Shock Absorber Inspection276
Rear Shock Absorber Spring Preload Adjustment278
Rear Shock Absorber Rebound Damping Force Adjustment280
Rear Shock Absorber Low Compression Damping Force Adjustment282
Rear Shock Absorber High Compression Damping Force Adjustment284
Tire Pressure Check286
Spokes Inspection And Tightening286
Wheel Inspection286
Steering Head Inspection And Adjustment288
Direction289
Lubrication294
Electrical296
Spark Plug Inspection296
Sistema Eléctrico297
Ignition Timing Check298
Battery Inspection And Charging300
Charging Method Using A Variable Voltage Charger308
Charging Method Using A Constant Voltage Charger309
Fuse Inspection316
Replacing The Headlight Bulbs318
Adjusting The Headlight Beams320
Sitzbank, Kraftstofftank321
Seat, Fuel Tank And Side Covers322
Side Cover Removal324
Exhaust Pipe And Silencer326
Tubo De Escape Y Silenciador327
Exhaust Pipe And Silencer Inspection328
Exhaust Pipe And Silencer Installation328
Auspuffkrümmer329
Y Silenciador329
Radiator330
Radiador331
Radiator Handling Note332
Radiator Inspection332
Radiator Assembly And Installation332
Carburetor336
Carburador337
Carburetor Diagram338
Carburetor Disassembly340
Carburetor Inspection344
Needle Valve Inspection346
Throttle Valve Inspection346
Jet Needle Inspection346
Float Height Inspection346
Carburetor Measurement And Adjustment Steps348
Float Inspection348
Starter Plunger Inspection348
Accelerator Pump Inspection350
Air Cut Valve Inspection350
Carburetor Assembly And Installation350
Accelerator Pump Timing Adjustment358
Carburetor Installation360
Air Induction System364
Air Induction System Inspection366
Sistema De Inducción De Aire367
Camshafts368
Cylinder Head Cover368
Ejes De Levas369
Camshafts Removal Points372
Camshafts Inspection374
Camshaft Sprocket Inspection376
Decompression System Check378
Timing Chain Tensioner Check378
Camshaft Assembly And Installation378
Cylinder Head386
Culata387
Cylinder Head Inspection388
Warpage Measurement And Resurfacement Steps388
Cylinder Head Assembly And Installation390
Valves And Valve Springs394
Soupapes Et Ressorts De Soupapes395
Ventile Und Ventilfedern395
Valve Lifter And Valve Cotter Removal396
Válvulas Y Muelles De Válvulas397
Valve Inspection398
Lapping Steps404
Valve Spring Inspection406
Valve Lifter Inspection406
Valves And Valve Springs Assembly And Installation408
Cylinder And Piston412
Piston Removal414
Piston Ring Removal414
Cylinder And Piston Inspection414
Cilindro Y Pistón415
Piston Ring Inspection418
Piston Pin Inspection420
Cylinder And Piston Assembly And Installation420
Cylinder Installation422
Clutch424
Embrague425
Clutch Removal Points428
Clutch Housing And Boss Inspection428
Primary Driven Gear Inspection428
Clutch Spring Inspection428
Friction Plate Inspection430
Clutch Plate Inspection430
Push Lever Inspection430
Push Rod Inspection430
Clutch Assembly And Installation432
Push Lever Installation432
Clutch Assembly432
Oil Filter, Water Pump And Crankcase Cover (Right)438
Filtro De Aceite439
Impeller Shaft Removal442
Oil Seal Removal442
Impeller Shaft Inspection442
Bearing Inspection444
Oil Seal Inspection444
Oil Filter, Water Pump And Crankcase Cover (Right) Assembly And Installation444
Impeller Shaft Installation446
Crankcase Cover (Right) Installation446
Y Tapa Del Cárter447
Kick Crank Installation448
Water Pump Housing Installation448
Oil Filter Installation450
Balancer452
Compensador453
Balancer Removal Points456
Primary Drive Gear, Balancer Drive Gear And Balancer Driven Gear Inspection456
Balancer Inspection456
Balancer Assembly And Installation458
Oil Pump460
Oil Pump Removal And Disassembly460
Bomba De Aceite461
Oil Pump Inspection464
Oil Pump Assembly And Installation464
Kick Axle And Shift Shaft468
Arbre De Kick Et Axe De Selecteur469
Kickhebelwelle Und Schaltwelle469
Eje Del Pedal De Arranque Y Eje Del Cambio469
Kick Axle And Shift Shaft Removal Points472
Kick Axle Assembly Removal472
Shift Guide And Shift Lever Assembly Removal472
Kick Axle And Ratchet Wheel Inspection472
Eje Del Pedal De Arranque473
Kick Gear, Kick Idle Gear And Ratchet Wheel Inspection474
Shift Shaft Inspection474
Shift Guide And Shift Lever Assembly Inspection474
Stopper Lever Inspect474
Y Eje Del Cambio475
Kick Axle And Shift Shaft Assembly And Installation476
Segment Installation476
Stopper Lever Installation476
Shift Guide And Shift Lever Assembly Installation476
Shift Shaft Installation478
Kick Axle Assembly Installation480
Kick Idle Gear Installation482
Ac Magneto And Starter Clutch484
Magneto Ca Y Embrague Del Motor De Arranque485
Lichtmaschine Und Starterkupplung485
Ac Magneto And Starter Clutch Removing Points488
Rotor Removal488
Starter Clutch Removal488
Ac Magneto Inspection488
Woodruff Key Inspection490
Starter Clutch Inspection490
Torque Limiter Check490
Ac Magneto And Starter Clutch Assembly And Installation492
Engine Removal498
Desmontaje Del Motor499
Drive Sprocket Removal504
Engine Removal Procedure504
Engine Installation506
Brake Pedal Installation506
Drive Sprocket Installation508
Crankcase And Crankshaft510
Cárter Y Cigüeñal511
Carter Moteur Et Vilebrequin511
Crankcase Bearing Diagram514
Caja De Cambios, Leva515
De Cambio Y Horquilla515
Crankcase Removal516
Balancer Shaft Removal516
Crankshaft Removal518
Crankshaft Bearing Removal518
Timing Chain And Timing Chain Guide Inspection518
Crankcase Inspection518
Crankshaft Inspection520
Oil Strainer Inspection520
Crankcase And Crankshaft Assembly And Installation522
Crankshaft Bearing Installation522
Crankshaft Installation522
Transmission, Shift Cam And Shift Fork528
Shift Fork, Shaft Cam And Transmission Removal530
Gears Inspection530
De Cambio531
Bearing Inspection (Transmission)532
Shift Fork, Shift Cam And Segment Inspection532
Transmission, Shift Cam And Shift Fork Assembly And Installation534
Front Wheel And Rear Wheel540
Front Wheel Diagram540
Rueda Delantera541
Roue Avant Et Roue Arriere541
Rear Wheel Diagram542
Y Rueda Trasera543
Rear Wheel Removal544
Rear Wheel Inspection544
Wheel Axle Inspection546
Brake Disc Inspection546
Front Wheel Assembly And Installation548
Rear Wheel Installation552
Front Brake And Rear Brake558
Front Brake Diagram558
Front Brake Removal558
Freno Delantero559
Frein Avant Et Frein Arriere559
Rear Brake Diagram560
Rear Brake Removal560
Y Freno Trasero561
Caliper Disassembly562
Master Cylinder Disassembly564
Front Brake And Rear Brake Removal Points566
Brake Fluid566
Caliper Piston Removal566
Piston Seal Removal568
Master Cylinder Inspection568
Caliper Inspection570
Brake Hose Inspection570
Caliper Piston Installation572
Rear Caliper Installation574
Master Cylinder Kit Installation576
Front Master Cylinder Installation578
Rear Master Cylinder Installation580
Front Brake Hose Installation582
Rear Brake Hose Installation584
Brake Fluid Fill586
Front Fork Diagram590
Front Fork Removal590
Horquilla Delantera591
Front Fork Disassembly592
Front Fork Handling Note594
Front Fork Removal Points594
Cap Bolt Removal594
Inner Tube Removal596
Damper Rod Removal596
Damper Rod Inspection596
Base Valve Inspection598
Fork Spring Inspection598
Inner Tube Inspection598
Outer Tube Inspection598
Cap Bolt Inspection600
Front Fork Assembly And Installation600
Front Fork Installation612
Handlebar Diagram616
Handlebar Removal616
Manillar617
Handlebar Removal Points618
Master Cylinder Removal618
Grip Removal618
Handlebar Inspection618
Handlebar Assembly And Installation620
Steering Diagram630
Steering Removal630
Dirección631
Steering Removal Points634
Ring Nut Removal634
Bearing (Lower) Removal, Bearing Race Removal634
Steering Shaft Inspection634
Bearing And Bearing Race Inspection636
Steering Assembly And Installation636
Under Bracket Installation636
Swingarm Diagram642
Swingarm Removal642
Basculante643
Swingarm Disassembly644
Swingarm Removal Points646
Cap Removal646
Bearing Removal (Swingarm)646
Swingarm Inspection646
Connecting Rod Inspection648
Swingarm Assembly And Installation648
Bearing And Oil Seal Installation648
Swingarm Installation650
Rear Shock Absorber Diagram658
Rear Shock Absorber Removal658
Amortiguador Trasero659
Et Caches Lateraux659
Tube D'echappement Et Silencieux659
Rear Shock Absorber660
Amortisseur Arriere661
Rear Shock Absorber Handling Note664
Rear Sock Absorber - Notes On Disposal (Yamaha Dealers Only)664
Rear Shock Absorber Removal Points666
Inspection Of The Rear Shock Absorber666
Rear Shock Absorber Assembly And Installation668
Spring (Rear Shock Absorber) Installation668
Rear Shock Absorber Installation670
Electrical Components And Wiring Diagram676
Partie Electrique677
Composants Electriques677
Et Schema De Cablage677
Ignition System - Inspection Steps678
Systeme D'allumage679
Sistema De Encendido681
Spark Gap Test682
Couplers, Leads And Ignition Coil Connection Inspection682
"Engine Stop" Button Inspection682
Main Switch Inspection684
Ignition Coil Inspection684
To Inspect The Ac Magneto686
Neutral Switch Inspection686
Cdi Unit Inspection686
Electric Starting System688
Starting System Cut-Off System Operation688
Demarrage Electrique689
Electric Starting System Inspection Steps690
Couplers And Leads Connection Inspection694
Starter Motor Operation694
Starting Circuit Cut-Off Relay Inspection694
Starter Relay Inspection696
Clutch Switch Inspection696
Diode Inspection698
Start Switch Inspection698
Starter Motor Diagram700
Starter Motor Removal700
Starter Motor Disassembly700
Electric Starting System Inspection And Repair704
Electric Starting System Assembly706
Charging System Inspection Steps710
Systeme De Charge711
Sistema De Carga713
To Inspect Couplers And Leads Connection714
Charging Voltage Inspection714
Tps (Throttle Position Sensor) System Inspection Steps716
Systeme Tps717
Couplers And Leads Connection Check720
Tps Coil Inspection720
Tps Replacement And Adjustment722
Tps Input Voltage Inspection726
Lighting System Inspection Steps728
Eclairage729
Beleuchtungsanlage730
Lighting System732
Checking The Taillight (Leds)732
Rectifier/Regulator Inspection734
Signaling System Inspection Steps736
Systeme De Signalisation737
Signalanlage738
Sistema De Señalización739
Couplers And Leads Connection - Inspection740
Multi-Function Display Input Voltage Inspection740
Multi-Function Display Output Voltage Inspection740
Kabelanschlüsse Kontrollieren741
Multifunktionsanzeige741
Speed Sensor Output Voltage Inspection742
Tuning746
Carburetor Setting746
Abstimmung747
Reglaje747
Atmospheric Conditions And Carburetor Settings Table748
Effects Of The Setting Parts On The Throttle Valve Opening750
Main System750
Main Jet Adjustment752
Effects Of Changing The Main Jet (Reference)752
Pilot Jet Adjustment752
Effects Of Adjusting The Pilot Jet (Reference)752
Jet Needle Groove Position Adjustment754
Effects Of Changing The Jet Needle Groove Position (Reference)754
Effects Of Changing The Jet Needle (Reference)756
Leak Jet Adjustment (Accelerator Pump Adjustment)756
Relationship With Throttle Opening758
Carburetor Setting Parts758
Examples Of Carburetor Setting Depending On Symptom760
Kraftstoff762
Combustible763
Chassis Setting764
Selection Of The Secondary Reduction Ratio (Sprocket)764
Drive And Driven Sprockets Setting Parts766
Tire Pressure766
Front Fork Setting768
Change In Level And Characteristics Of Fork Oil768
Spring Preload Adjustment770
Setting Of Spring After Replacement772
Use Of Soft Spring772
Use Of Stiff Spring772
Front Fork Setting Parts774
Rear Suspension Setting776
Choosing Set Length776
Setting Of Spring After Replacement (Rear Suspension)778
Federbein781
Rear Shock Absorber Setting Parts782
Suspension Setting - Front Fork784
Rear Shock Absorber Symptoms785