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Yamaha WR45OFR service manual Electrical Components, TPS Throttle Position Sensor

Models: WR45OFR

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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

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Yamaha WR45OFR service manual Electrical Components, TPS Throttle Position Sensor

Contents

WR450FR Page By Yamaha Motor Corporation, U.S.A 1st Edition, October WR450FRLIT-11626-16-43 Introduction Page Always Wear Protective Apparel Always Maintain Your Machine in Proper Working OrderPark the Machine Carefully Turn OFF the Engine Gasoline can Cause InjuryProperly Secure the Machine Before Transporting IT M. Machine Weights Weights of machines without fuelParticularly Important Information Finding the RequiredHOW to Read Descriptions Manual FormatGEN Spec Info Insp ENG ADJ Memo Index Chapter Regular Inspection Adjustments SEAT, Fuel Tank Side Covers Front Wheel and Rear Wheel Front Brake and Rear BrakeElectrical Components TPS Throttle Position SensorDescription Info DescriptionMachine Identification Vehicle Identification NumberEngine Serial Number Model LabelPreparation for Removal and Disassembly Important InformationALL Replacement Parts Lock WASHERS/PLATES and Cotter PinsGASKETS, OIL Seals and O-RINGS Bearings and OIL SealsCirclips Checking of Connection Part number Tool name/How to use Illustration Special ToolsGEN Info ACC-QUICK-GS-KT Main Switch Main switch indicator lightStart Switch Control FunctionsClutch Lever Shift PedalKickstarter Throttle GripRear Brake Pedal Fuel CockCold Starter Knob HOT Starter LeverLights Switch Valve JointSpark Plug Wrench Nipple WrenchFuel Starting and BREAK-IN AIR Filter MaintenanceStarting a Cold Engine Do not warm up the engine for extended periods of time Restarting an engine after a fall Starting a Warm EngineEngine fails to start BREAK-IN Procedures Cylinder and CrankshaftAbout one hour of break-in operation is necessary PISTON, RING, VALVES, Camshafts and GearsTORQUE-CHECK Points Cleaning and Storage CleaningStorage General Specifications 5TJ4 CDN, AUS, NZ, ZAFCR MX39 CDI Maintenance Specifications EngineSeat Width 7083 ~ 0.7087 7075 Spec USA CDN, AUS, NZ Spec Standard Lubrication chart Part to be tightened Thread size ’ty Tightening torque Oil strainer frame Chassis USA, CDN Europe AUS, NZ, ZADID520VM/DAIDO Handle crown and outer tube Rear wheel axle and nut M4 ⋅ Electrical 5TA-00/DENSOACM33221 M06/MATSUSHITA General Torque Specifications Definition of UnitsTorque Mkg Ftlb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 16 mm 130Lubrication Diagrams Spec Cable Routing Diagram Spec Spec Spec Spec Spec Maintenance Intervals Insp ADJShift FORK, Shift CAM, Guide BAR Marked For USA PRE-OPERATION Inspection and Maintenance General Inspection and MaintenanceCoolant Replacement Do not remove the radiator cap when the engine is hotEngine Coolant Level InspectionCoolant Replacement Fill Radiator Engine To specified level Radiator CAP Opening Pressure Inspection Radiator CAP InspectionRadiator cap opening pressure 110 kPa 1.1 kg/cm2, 15.6 psi Cooling System Inspection Cooling System InspectionStandard pressure KPa 1.8 kg/cm2, 25.6 psi Clutch Adjustment Throttle Cable AdjustmentHOT Starter Lever Adjustment Hot starter lever free play adjustment stepsThrottle Lubrication Hot starter lever free play a 3 ~ 6 mm 0.12 ~ 0.24AIR Filter Cleaning AIR Filter CleaningInsp ADJ Engine OIL Level Inspection Engine OIL Level InspectionWhen the oil tank is empty, never start the engine Recommended oilRecommended engine oil classi- fication API StandardEngine OIL Replacement Engine OIL ReplacementReplacement steps Oil filter cover 10 Nm 1.0 m kg, 7.2 ft lbPilot Screw Adjustment Pilot Screw AdjustmentAdjustment steps Idle Speed AdjustmentValve Clearance Adjustment Valve Clearance Adjustment Mm increments Pad range Pad Availability Increments 20 mm40 mm Example Last digit of pad Rounded valueBolt camshaft cap 10 Nm 1.0 m kg, 7.2 ft lb Insp ADJ Intake ExhaustSpark Arrester Cleaning For USA Chassis CHASSIS/BRAKE System AIR BleedingBrake System AIR Bleeding Front Brake Adjustment Front Brake AdjustmentBrake lever position adjustment steps Locknut Nm 0.5 m kg, 3.6 ft lbRear Brake Adjustment Front Brake PAD Inspection and ReplacementDo not reuse the drained brake fluid Front Brake PAD Inspection and ReplacementBleed screw Nm 0.6 m kg, 4.3 ft lb Rear Brake PAD Inspection and Replacement Rear Brake PAD Inspection and ReplacementPad pin plug Nm 0.3 m kg, 2.2 ft lb Brake pad thickness a Standard Limit Mm 0.25 Mm 0.04Pad pin 18 Nm 1.8 m kg, 13 ft lb Rear Brake PAD Insulator Inspection Brake Fluid Level InspectionSprockets INSPECTION/DRIVE Chain Inspection Sprockets InspectionDrive Chain Inspection Drive chain length 10 links Limit 150.1 mm 5.91Drive Chain Inspection Drive Chain Slack Adjustment Drive Chain Slack AdjustmentDrive chain slack adjustment steps Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0Front Fork OIL Seal and Dust Seal Cleaning Axle nut 125 Nm 12.5 m kg, 90 ft lbLocknut 16 Nm 1.6 m kg, 11 ft lb Front Fork InspectionFront Fork Rebound Damping Force Adjustment Front Fork Internal Pressure RelievingFront Fork Compression Damping Force Adjustment Standard position 10 clicks out Clicks outRear Shock Absorber Inspection Rear Shock Absorber Inspection246 mm 9.69 240.5 ~ 258.5 mm Rear Shock Absorber Spring Preload Adjustment47 ~ 10.18 Rear Shock Absorber Rebound Damping Force Adjustment Standard position About 9 clicks out *About 10 clicks outRear Shock Absorber LOW Compression Damping Force Adjustment Standard position About 6 clicks out *About 13 clicks outEC36d000 Tire Pressure Check Standard tire pressure KPa 1.0 kgf/cm2, 15 psiSpokes Inspection and Tightening Wheel InspectionSteering Head Inspection and Adjustment Steering Head Inspection AdjustmentSteering ring nut adjustment steps Ring nut wrench YU-33975/90890-01403Cautio N Lubrication LubricationELECTRICAL/SPARK Plug Inspection ElectricalSpark Plug Inspection Spark plug gap ~ 0.8 mm 0.028 ~ 0.031Ignition Timing Check Ignition Timing CheckBattery Inspection and Charging Battery Inspection and ChargingKeep Batteries and Electrolyte OUT of Reach of Children First AID in Case of Bodily Contact ExternalMeasurement steps Do not quick charge a battery ExampleInsp ADJ Charging method using a variable voltage charger Charging method using a constant voltage charger Fuse Inspection First, connect the positive lead 1, then the negative leadRecommended lubricant Lithium soap base grease Fuse InspectionItems Amperage ’ty Rating Replacing the Headlight BulbsReplacing the Headlight Bulbs Adjusting the Headlight Beams Adjusting the Headlight BeamsSEAT, Fuel Tank and Side Covers SEAT, Fuel Tank and Side Covers RemovalRemoval Points Side coverExhaust Pipe and Silencer Exhaust Pipe Silencer RemovalAssembly and Installation Exhaust pipe and silencer Exhaust pipe and silencerRadiator Radiator RemovalHandling Note Assembly and Installation RadiatorRadiator Install Radiator breather hose Radiator right Carburetor Carburetor RemovalCarburetor Disassembly Carburetor DisassemblyENG Pilot screw CarburetorNeedle valve Throttle valveJet needle Standard clip position No.4 GrooveFloat Measurement and adjustment stepsStarter plunger Accelerator pump Assembly and Installation CarburetorAir cut valve ENG ENG Pilot screw 4 turns out example 2 turns out example ENG Accelerator pump timing adjustment Adjustment steps Carburetor installationCarburetor ENG Throttle valve height Mm 0.122Tighten Screw air cleaner joint Cylinder Head Cover CamshaftsCylinder Head Cover Removal Camshafts Removal Camshaft Runout camshaft Less than 0.03 mm 0.0012 Bolt camshaft cap 10 Nm 1.0 m kg, 7.2 ft lb Assembly and Installation Installation stepsDecompression system Timing chain tensionerCA U TI on Bolt camshaft capBolt timing chain tensioner Camshafts ENGTensioner cap bolt Cylinder Head Cylinder Head RemovalCylinder head Bolts cylinder head 1st 30 Nm 3.0 m kg, 22 ft lb Bolts cylinder head 2nd20 Nm 2.0 m kg, 14 ft lb FinalValves and Valve Springs Valves and Valve Springs RemovalValve spring compressor YM-4019/90890-04019 Valve ENG Runout limit 01 mm 0.0004 Lapping steps Valve spring Combination of cylinder head and valve lifter Combination Cylinder head mark Valve lifter mark ColorYellow BlackCA UT ION Cylinder and Piston Cylinder and Piston RemovalPiston Piston pin puller YU-1304/90890-01304Do not use a hammer to drive the piston pin out Piston ring Cylinder and pistonCylinder bore C 95.00 ~ 95.01 mm 7402 ~ 3.7406 05 mm 0.0022nd step Piston size P StandardEnd gap Standard Limit 2nd ring 020 ~ 0.055 mm 12 mm 0008 ~ 0.002220 ~ 0.50 mm 01 ~ 0.02 Piston pin Inside diameter piston 18.004 ~ 18.015 mm 0.7088 ~ 0.7093Cylinder Clutch Clutch RemovalENG Clutch housing and boss Clutch bossClutch holding tool YM-91042/90890-04086 Primary driven gearFriction plate Clutch plateWarp limit Mm 0.004 Push lever Push rodAssembly and Installation Push lever ClutchENG Install Clutch spring Bolt clutch spring OIL FILTER, Water Pump and Crankcase Cover Right OIL FILTER, Water Pump and Crankcase Cover RightOIL FILTER, Water Pump Crankcase Cover Right Removal ENG Impeller shaft Oil sealBearing Crankcase cover right Water pump housing Kick crankOil filter Balancer Balancer RemovalBalancer drive gear and balancer driven gear BalancerBalancer, balancer drive gear and balancer driven gear OIL Pump Removal and DIS Assembly OIL PumpENG Assembly and Installation Oil pump Oil pumpBolt oil pump assembly L = 25 mm 0.98 Kick Axle and Shift Shaft Kick Axle and Shift Shaft RemovalENG Kick axle assembly Shift guide and shift lever assemblySegment Kick axle and ratchet wheelShift shaft Assembly and Installation SegmentStopper lever Install Torsion spring Stopper lever Bolt stopper lever EC4C5301 Kick idle gear AC Magneto and Starter Clutch AC Magneto and Stator RemovalENG Rotor Rotor puller YM-04141/90890-04141AC magneto Woodruff keyAssembly and Installation AC magneto and starter clutch Starter clutchQuick gasket ACC-QUICK-GS-KT Yamaha Bond No 90890-85505 Install Bolt starter clutch Install Engine guard Clamp Bolt engine guard front Engine Removal Engine RemovalENG ENG Drive sprocket Engine removalAssembly and Installation Engine installation Brake pedalInstall Ring 1 New Dowel pin Oil hose Bolt oil hose Crankcase and Crankshaft Crankcase SeparationENG Crankcase Bearing Crankcase Bearing RemovalCrankcase Separation stepsCrankcase separating tool YU-1135-A/90890-01135 CrankshaftTiming chain and timing chain guide Oil delivery pipe Assembly and Installation Crankshaft bearing Do not use a hammer to drive in the crank- shaft Quick gasket ACC-QUICK-GS-KT Yamaha Bond NoBolt crankcase TRANSMISSION, Shift CAM and Shift Fork TRANSMISSION, Shift CAM and Shift ForkTRANSMISSION, Shift CAM Shift Fork Removal Shift fork, shaft cam and transmission GearsAssembly and Installation Transmission Shift fork, shift cam and segmentENG ENG Front Wheel and Rear Wheel Chas Front Wheel and Rear WheelFront Wheel Front Wheel RemovalRear Wheel Rear Wheel RemovalWheel bearing if necessary Rear wheelWheel Wheel axle Wheel axle bending limit 0.5 mm 0.020Do not attempt to straighten a bent axle Brake discCaacuhtutionng Front wheel105 Nm 10.5 m · kg, 75 ft · lb Tighten Bolt axle holder Tighten the nuts in stage, using a crisscross pattern Front Wheel and Rear Wheel Chas Adjust Drive chain slack a Front Brake and Rear Brake Chas Front Brake and Rear BrakeFront Brake Front Brake RemovalRear Brake Rear Brake RemovalCaliper Disassembly Caliper DisassemblyMaster Cylinder Disassembly Master Cylinder Disas SemblyBrake fluid Caliper pistonMaster cylinder Piston seal kitUse only new brake fluid Caliper Brake hoseAlways use new piston seals and dust seals Front caliperAlways use new copper washers Rear caliperMaster cylinder kit Front master cylinder Caauchtutionng Rear master cylinderFront brake hose Cauachttuniong Install Brake hose holder Screw brake hose holder Rear Diaphragm Master cylinder cap Bolt master cylinder cap Front Fork Front Fork ChasFront Fork Removal Front Fork Disassembly Front Fork DisassemblyCap bolt Inner tube Take care not to scratch the inner tubeOil seal removal steps Damper rodBase valve Fork springInner tube bending limit 0.2 mm 0.008 Outer tubeAssembly and Installation Front fork assembly Front Fork Chas Fork seal driver YM-01442/90890-01442 Recommended oil Suspension oil Front Fork Chas Front Fork Chas Installation Front fork top end standard a Zero mm ZeroTighten Pinch bolt handle crown Handlebar Handlebar ChasHandlebar Removal Grip HandlebarAssembly and Installation Handlebar Install Cover grip cap Cover throttle cable cap Hot starter lever holder Bolt hot starter lever holder Handlebar Chas Steering Steering ChasSteering Removal Steering Chas Ring nut Bearing lowerTake care not to damage the steering shaft thread Ball raceBearing and ball race Under bracketInstall Plain washer Ring nut Install Trip meter Bolt trip meter Swingarm Swingarm ChasSwingarm Removal Swingarm Disassembly Swingarm DisassemblySwingarm Relay armConnecting rod Bearing and oil sealInstalled depth of bearings a 5 mm 0.20 Installed depth of bearings a 5 mm 0.20 Swingarm80 Nm 8.0 m · kg, 58 ft · lb Tighten Nut relay arm Bolt support cover r= 10 mm 0.39 Rear Shock Absorber Rear Shock Absorber ChasRear Shock Absorber Removal Rear Shock Absorber Chas Rear Shock Absorber Chas EC586000 Rear shock absorber Installed depth of the bearing a 4 mm 0.16 Spring rear shock absorberSpring length installed a Standard Extent AdjustmentBolt rear frame lower Rear Shock Absorber Chas Wiring Diagram Electrical Components and Wiring DiagramColor Code MAP-CONTROLLED CDI Unit Function of ComponentIgnition System Inspection StepsIgnition System Elec + Spark GAP TestCOUPLERS, Leads and Ignition Coil Connection Inspection Engine Stop Button InspectionOFF Main Switch InspectionIgnition Coil Inspection AC Magneto Inspection Neutral Switch InspectionCDI Unit Inspection Electric Starting System Starting Circuit CUT-OFF System OperationInspection Steps Couplers and Leads Connection Inspection Starter Motor OperationStarting Circuit CUT-OFF Relay Inspection Tor positionStarter Relay Inspection Clutch Switch InspectionPull Free Remove the diode from wire harness Start Switch InspectionElectric Starting System Elec + Diode InspectionStarter Motor Removal Starter MotorStarter Motor Disassem BLY Elec Min. commutator diameter 16.6 mm 0.65 Inspection and RepairMica undercut 1.5 mm 0.06 Be careful not to damage the brush during installation AssemblyMin. brush length Mm 0.14 New Charging System Charging Voltage Inspection Tester + lead → Red lead Tester lead → Black leadDCV-20 000 r/minTPS Throttle Position Sensor System TPS Throttle Position Sensor System Elec + TPS Coil InspectionTPS Replacement and Adjustment Tester + lead → Yellow lead Tester lead → Black lead58 ~ 0.78 DCVTester + lead → Blue lead 1 Tester lead → Black/Blue lead TPS Input Voltage Inspection~ 6 DCV-20 Lighting System Lights Switch Inspection Tester + lead → Yellow lead Tester lead → Blue leadNo continuous while being → Replace RECTIFIER/REGULATOR InspectionSetting Carburetor settingHumidity Effects of the setting parts on the throttle valve opening Setting T U NMain system Main jet adjustment Pilot systemStandard main jet #150 #160 Effects of changing the main jet referenceEffects of adjusting the pilot screw reference Pilot screw adjustmentStandard pilot Screw position Example Pilot jet adjustment Effects of adjusting the pilot jet referenceJet needle groove position adjustment Standard pilot jet #45 #48Jet needle adjustment Standard jet needleObdut Obduq Effects of changing the jet needle referenceSTD #DUS#DUV #DUWExamples of carburetor setting depending on symptom Selection of the secondary reduction ratio Sprocket Standard secondary reduction ratio 50/145NG-17460-00 9383E-14215For CDN, EUROPE, AUS, NZ and ZA Size Part numberFront fork setting Change in level and characteristics of fork oilSpring preload adjustment Setting of spring after replacementSetting Part Number SpringMark RateChoosing set length Rear suspension settingStandard ﬁgure 90 ~ 100 mm 3.5 ~ 3.9 EC72G001 Setting Adjustment b Rear shock absorber setting partsSpring Free Extent Suspension setting One passenger is astride seat Printed on Recycled Paper Shingai Iwata Shizuoka Japan