Yamaha WR450FG Manuals

Manuals and User Guides for Yamaha WR450FG. We have 1 Yamaha WR450FG manual available for free PDF download: Owner's Service Manual

Yamaha WR450FG Owner's Service Manual

Yamaha WR450FG Owner's Service Manual (426 pages)

Brand: Yamaha | Category: Motorcycle | Size: 14.08 MB

Table of Contents

Table of Contens 1

11
- Important Manual Information
  6
- Safety Information
  7
- How to Use this Manual
  8
- Table of Contents
  11
- General Information
  13
  - Location of Important Labels
    15
  - Description
    18
  - Identification
    19
    
    Vehicle Identification Number
    19
    
    Engine Serial Number
    19
    
    Vehicle Emission Control Information Label
    19
  - Included Parts
    20
    
    Spark Plug Wrench
    20
    
    Nipple Wrench
    20
    
    Handlebar Protector
    20
    
    Fuel Hose Joint Cover
    20
    
    Coupler for Connecting Optional Part
    20
  - Important Information
    21
    
    Preparation for Removal and Disassembly
    21
    
    Replacement Parts
    21
    
    Gaskets, Oil Seals and O-Rings
    22
    
    Lock Washers/Plates and Cotter Pins
    22
    
    Bearings and Oil Seals
    22
    
    Circlips
    22
  - Basic Service Information
    23
    
    Electrical System
    23
  - Special Tools
    27
  - Control Functions
    32
    
    Indicator Lights and Warning Lights
    32
    
    Engine Stop Switch
    32
    
    Start Switch
    32
    
    Clutch Lever
    32
    
    Shift Pedal
    33
    
    Kickstarter Lever
    33
    
    Throttle Grip
    33
    
    Front Brake Lever
    33
    
    Rear Brake Pedal
    33
    
    Sidestand
    34
    
    Starter Knob/Idle Screw
    34
    
    Fuel Tank Cap
    34
  - Multi-Function Display
    35
    
    Description
    35
    
    Basic Mode
    35
    
    Changeover to Basic Mode/Race Mode
    36
    
    Race Mode
    37
    
    Function Diagram
    40
  - Starting and Break-In
    42
    
    Fuel
    42
    
    Handling Note
    42
    
    Air Filter Maintenance
    42
    
    Starting a Cold Engine
    42
    
    Starting a Warm Engine
    44
    
    Break-In Procedures
    44
  - Maintenance after Break-In
    45
    
    Major Maintenance
    45
  - Torque-Check Points
    46
  - Motorcycle Care and Storage
    48
    
    Care
    48
    
    Storage
    49
Specifications

51
- General Specifications
  52
- Engine Specifications
  53
- Chassis Specifications
  58
- Electrical Specifications
  61
- Tightening Torques
  63
- Lubrication Points and Lubricant Types
  72
  - Engine
    72
  - Chassis
    73
- Lubrication System Chart and Diagrams
  76
  - Lubrication Diagrams
    76
- Cable Routing Diagram
  84
Periodic Checks and Adjustments

97
- Periodic Maintenance
  
  99
- Pre-Operation Inspection and Maintenance
  
  107
  - General Inspection and Maintenance
    107
- Engine
  
  108
  - Checking the Coolant Level
    108
  - Checking the Cooling System
    108
  - Changing the Coolant
    108
  - Checking the Radiator Cap
    109
  - Checking the Radiator Cap Valve Opening Pressure
    109
  - Checking the Coolant Circulatory System for Leaks
    110
  - Adjusting the Clutch Lever Free Play
    110
  - Adjusting the Throttle Grip Free Play
    111
  - Lubricating the Throttle Cable
    112
  - Cleaning the Air Filter Element
    112
  - Checking the Throttle Body Joint
    113
  - Checking the Breather Hoses
    113
  - Checking the Exhaust System
    113
  - Checking the Fuel Line
    114
  - Checking the Engine Oil Level
    114
  - Changing the Engine Oil
    115
  - Adjusting the Engine Idling Speed
    117
  - Adjusting the Valve Clearance
    118
  - Cleaning the Spark Arrester
    122
- Chassis
  
  123
  - Bleeding the Brake System
    123
  - Checking the Brake Hose
    124
  - Adjusting the Front Brake
    124
  - Adjusting the Rear Brake
    125
  - Checking the Front Brake Pads
    125
  - Checking the Rear Brake Pads
    127
  - Checking the Rear Brake Pad Insulator
    128
  - Checking the Brake Fluid Level
    128
  - Adjusting the Drive Chain Slack
    129
  - Checking the Front Fork Legs
    129
  - Checking the Front Fork Protector Guide
    130
  - Cleaning the Front Fork Oil Seal and Dust Seal
    130
  - Air Bleeding from Front Fork
    130
  - Adjusting the Front Fork Legs
    131
  - Checking the Swingarm Operation
    132
  - Checking the Rear Suspension
    132
  - Adjusting the Rear Shock Absorber Assembly
    132
  - Checking the Tires
    134
  - Checking and Tightening the Spokes
    134
  - Checking the Wheels
    135
  - Checking the Wheel Bearings
    135
  - Checking and Adjusting the Steering Head
    135
  - Checking and Lubricating the Cables
    136
  - Lubricating the Levers
    136
  - Lubricating the Pedal
    136
  - Lubricating the Drive Chain
    137
  - Lubricating the Sidestand
    137
  - Checking the Chassis Fasteners
    137
- Electrical System
  
  138
  - Checking the Spark Plug
    138
  - Checking the Ignition Timing
    138
  - Checking and Charging the Battery
    139
  - Replacing the Headlight Bulb
    139
Tuning

141
- Chassis
  142
  - Selection of the Secondary Reduction Ratio (Sprocket)
    142
  - Drive and Rear Wheel Sprockets Setting Parts
    142
  - Tire Pressure
    142
  - Front Fork Setting
    143
  - Change in Amount and Characteristics of Fork Oil
    143
  - Setting of Spring after Replacement
    143
  - Front Fork Setting Parts
    144
  - Rear Suspension Setting
    144
  - Choosing Set Length
    144
  - Setting of Spring after Replacement
    145
  - Rear Shock Absorber Setting Parts
    145
  - Suspension Setting (Front Fork)
    147
  - Suspension Setting (Rear Shock Absorber)
    148
Chassis

151
- General Chassis
  
  155
  - Removing the Left Side Cover
    155
  - Removing the Seat
    155
- Front Wheel
  
  157
  - Removing the Front Wheel
    157
  - Checking the Front Wheel
    157
  - Disassembling the Front Wheel
    158
  - Assembling the Front Wheel
    158
  - Installing the Front Wheel
    159
- Rear Wheel
  
  162
  - Removing the Rear Wheel
    162
  - Checking the Rear Wheel
    162
  - Disassembling the Rear Wheel
    162
  - Checking and Replacing the Rear Wheel Sprocket
    162
  - Assembling the Rear Wheel
    163
  - Installing the Rear Wheel
    163
- Front Brake
  
  165
- Rear Brake
  
  175
- Handlebar
  
  187
  - Removing the Handlebar
    187
  - Checking the Handlebar
    187
  - Installing the Handlebar
    187
- Front Fork
  
  192
  - Removing the Front Fork Legs
    194
  - Disassembling the Front Fork Legs
    194
  - Checking the Front Fork Legs
    195
  - Assembling the Front Fork Legs
    196
  - Installing the Front Fork Legs
    202
- Steering Head
  
  205
  - Removing the Lower Bracket
    207
  - Checking the Steering Head
    207
  - Installing the Steering Head
    207
- Rear Shock Absorber Assembly
  
  210
- Swingarm
  
  217
  - Removing the Swingarm
    218
  - Removing the Bearing
    218
  - Checking the Swingarm
    218
  - Installing the Swingarm
    219
- Chain Drive
  
  220
  - Removing the Drive Chain
    221
  - Checking the Drive Chain
    221
  - Checking the Drive Sprocket
    222
  - Checking the Rear Wheel Sprocket
    222
  - Installing the Drive Chain
    222
Engine

225
- Engine Removal
  
  228
  - Removing the Drive Sprocket
    233
  - Removing the Exhaust Pipe 2
    233
  - Removing the Silencer
    233
  - Cleaning the Spark Arrester
    234
  - Removing the Engine
    234
  - Checking the Silencer and Exhaust Pipe
    235
  - Installing the Engine
    235
  - Installing the Brake Pedal
    236
  - Installing the Drive Sprocket
    236
  - Installing the Exhaust Pipe and Muffler
    236
- Camshaft
  
  238
  - Removing the Camshaft
    240
  - Checking the Camshaft
    241
  - Checking the Timing Chain and Camshaft Sprocket
    242
  - Checking the Timing Chain Tensioners
    242
  - Checking the Decompression System
    243
  - Installing the Camshafts
    243
- Cylinder Head
  
  245
- Valves and Valve Springs
  
  251
  - Removing the Valves
    251
  - Checking the Valves and Valve Guides
    252
  - Checking the Valve Seats
    253
  - Checking the Valve Springs
    255
  - Checking the Valve Lifters
    256
  - Installing the Valves
    256
- Cylinder and Piston
  
  259
  - Removing the Piston
    259
  - Checking the Cylinder and Piston
    259
  - Checking the Piston Rings
    260
  - Checking the Piston Pin
    261
  - Installing the Piston and Cylinder
    261
- Electric Starter
  
  263
  - Checking the Starter Motor
    265
  - Assembling the Starter Motor
    266
- Clutch
  
  271
  - Removing the Clutch
    271
  - Checking the Friction Plates
    271
  - Checking the Clutch Plates
    271
  - Checking the Clutch Springs
    271
  - Checking the Clutch Housing
    272
  - Checking the Clutch Boss
    272
  - Checking the Pressure Plate
    272
  - Checking the Push Lever Shaft
    272
  - Checking the Clutch Push Rods
    272
  - Checking the Primary Drive Gear
    272
  - Checking the Primary Driven Gear
    273
  - Installing the Oil Seal
    273
  - Installing the Right Crankcase Cover
    273
  - Installing the Clutch
    273
  - Installing the Kickstarter Lever
    276
- Kickstater
  
  278
- Shift Shaft
  
  281
  - Removing the Shift Guide and Shift Lever Assembly
    281
  - Removing the Segment
    281
  - Checking the Shift Shaft
    281
  - Checking the Shift Guide and Shift Lever Assembly
    281
  - Checking the Stopper Lever
    281
  - Installing the Stopper Lever
    282
  - Installing the Segment
    282
  - Installing the Shift Guide and Shift Lever Assembly
    282
  - Installing the Shift Shaft
    283
  - Installing the Shift Pedal
    283
- Oil Pump and Balancer Gear
  
  285
- Generator and Starter Clutch
  
  292
  - Removing the Generator
    292
  - Checking the Starter Clutch
    292
  - Installing the Starter Clutch
    293
  - Installing the Generator
    294
- Crankcase
  
  297
  - Disassembling the Crankcase
    299
  - Removing the Crankcase Bearing
    299
  - Checking the Timing Chain, Timing Chain Guide, Oil Strainer
    299
  - Checking the Crankcase
    299
  - Installing the Oil Seal
    300
  - Assembling the Crankcase
    300
- Crankshaft Assembly and Balancer Shaft
  
  301
- Transmission
  
  305
  - Removing the Transmission
    305
  - Checking the Shift Forks
    305
  - Checking the Shift Drum Assembly
    306
  - Checking the Transmission
    306
  - Installing the Transmission
    306
  - Cooling System
    309
    
    Water Pump
    314
Fuel System

317
- Fuel Tank
  
  318
  - Checking the Fuel Pump Body
    320
  - Installing the Fuel Pump
    320
  - Removing the Fuel Pump
    320
  - Removing the Fuel Tank
    320
  - Checking the Fuel Sender
    321
  - Installing the Fuel Sender
    321
  - Installing the Fuel Tank
    321
  - Removing the Fuel Sender
    321
  - Checking the Damper
    322
  - Checking the Fuel Pressure
    322
  - Checking and Replacing the Protector
    323
- Throttle Body
  
  324
  - Checking the Injector
    327
  - Checking the Throttle Body
    327
  - Checking the Throttle Body Joint
    327
  - Adjusting the Throttle Position Sensor
    328
  - Installing the Injector
    328
Electrical System

329
- Ignition System
  
  332
  - Circuit Diagram
    332
  - Troubleshooting
    334
- Electric Starting System
  
  336
  - Circuit Diagram
    336
  - Starting Circuit Cut-Off System Operation
    338
  - Troubleshooting
    340
- Charging System
  
  342
  - Circuit Diagram
    342
  - Troubleshooting
    344
- Lighting System
  
  346
  - Circuit Diagram
    346
  - Troubleshooting
    348
- Signaling System
  
  350
  - Circuit Diagram
    350
  - Troubleshooting
    352
- Cooling System
  
  354
  - Circuit Diagram
    354
  - Troubleshooting
    356
- Fuel Injection System
  
  358
  - Circuit Diagram
    358
  - Ecu Self-Diagnostic Function
    360
  - Troubleshooting Method
    361
  - Yamaha Diagnostic Tool
    362
  - Troubleshooting Details
    365
- Fuel Pump System
  
  386
  - Circuit Diagram
    386
  - Troubleshooting
    388
- Electrical Components
  
  390
  - Checking the Switches
    394
  - Checking the Bulbs and Bulb Sockets
    397
  - Checking the Fuses
    398
  - Checking and Charging the Battery
    399
  - Checking the Relays
    402
  - Checking the Diode
    403
  - Checking the Ignition Spark Gap
    403
  - Checking the Spark Plug Cap
    403
  - Checking the Ignition Coil
    404
  - Checking the Crankshaft Position Sensor
    404
  - Checking the Lean Angle Sensor
    405
  - Checking the Starter Motor Operation
    405
  - Checking the Stator Coil
    406
  - Checking the Rectifier/Regulator
    406
  - Checking the Speed Sensor
    407
  - Checking the Fuel Sender
    407
  - Checking the Resister
    407
  - Checking the Radiator Fan Motor
    408
  - Checking the Coolant Temperature Sensor
    408
  - Checking the Throttle Position Sensor
    409
  - Checking the Throttle Position Sensor Input Voltage
    409
  - Checking the Intake Air Pressure Sensor
    410
  - Checking the Intake Air Temperature Sensor
    410
  - Checking the Fuel Injector
    411
Troubleshooting

413
- General Information
  413
- Troubleshooting
  
  414
  - General Information
    414
  - Starting Failures
    414
  - Incorrect Engine Idling Speed
    414
  - Poor Medium-And-High-Speed Performance
    415
  - Shifting Is Difficult
    415
  - Shift Pedal Does Not Move
    415
  - Jumps out of Gear
    415
  - Clutch Slips
    415
  - Clutch Drags
    415
  - Overheating
    415
  - Overcooling
    416
  - Poor Braking Performance
    416
  - Front Fork Oil Leaking
    416
  - Faulty Front Fork Legs
    416
  - Unstable Handling
    416
  - Headlight Does Not Come on
    417
  - Headlight Bulb Burnt out
    417
  - Taillight Does Not Come on
    417
- List of Self-Diagnostic and Fail-Safe Actions
  
  419

Advertisement

Advertisement

Related Products

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals