Cylinder and Piston Removal | Yamaha WR45OFR manual

CYLINDER AND PISTON

CYLINDER AND PISTON

CYLINDER AND PISTON

ENG

Extent of removal:								1 Cylinder removal		2 Piston removal

Extent of removal							Order	Part name	Q’ty		Remarks

								CYLINDER AND PISTON
								REMOVAL
Preparation for removal								Cylinder head			Refer to “CYLINDER HEAD” section.

							1	Bolt (cylinder)	1
							1	Bolt (cylinder)	1
	1						2	Cylinder	1
							2	Cylinder	1
							3	Gasket	1
							4	Dowel pin	2
							5	Dowel pin/O-ring	1/1
				2			5	Dowel pin/O-ring	1/1
							6	Piston pin clip	2
							6	Piston pin clip	2
							7	Piston pin	1		Use special tool.
							8	Piston	1		Refer to “REMOVAL POINTS”.
							9	Piston ring set	1
							9	Piston ring set	1

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Yamaha WR45OFR service manual Cylinder and Piston Removal

Contents

WR450FR Page WR450FR By Yamaha Motor Corporation, U.S.A 1st Edition, OctoberLIT-11626-16-43 Introduction Page Always Maintain Your Machine in Proper Working Order Always Wear Protective Apparel Gasoline can Cause Injury Park the Machine Carefully Turn OFF the EngineProperly Secure the Machine Before Transporting IT Weights of machines without fuel M. Machine Weights Finding the Required Particularly Important Information Manual Format HOW to Read Descriptions GEN Spec Info Insp ENG ADJ Memo Index Chapter Regular Inspection Adjustments Front Wheel and Rear Wheel Front Brake and Rear Brake SEAT, Fuel Tank Side Covers TPS Throttle Position Sensor Electrical Components Description Description Info Vehicle Identification Number Machine IdentificationEngine Serial Number Model Label Important Information Preparation for Removal and Disassembly Lock WASHERS/PLATES and Cotter Pins ALL Replacement PartsGASKETS, OIL Seals and O-RINGS Bearings and OIL Seals Circlips Checking of Connection Special Tools Part number Tool name/How to use Illustration GEN Info ACC-QUICK-GS-KT Main switch indicator light Main SwitchStart Switch Control Functions Shift Pedal Clutch LeverKickstarter Throttle Grip Fuel Cock Rear Brake PedalCold Starter Knob HOT Starter Lever Valve Joint Lights SwitchSpark Plug Wrench Nipple Wrench Fuel AIR Filter Maintenance Starting and BREAK-INStarting a Cold Engine Do not warm up the engine for extended periods of time Starting a Warm Engine Restarting an engine after a fallEngine fails to start Cylinder and Crankshaft BREAK-IN ProceduresAbout one hour of break-in operation is necessary PISTON, RING, VALVES, Camshafts and Gears TORQUE-CHECK Points Cleaning Cleaning and Storage Storage 5TJ4 CDN, AUS, NZ, ZA General Specifications FCR MX39 CDI Engine Maintenance Specifications Seat 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 USA, CDN Europe AUS, NZ, ZA Chassis DID520VM/DAIDO Handle crown and outer tube Rear wheel axle and nut M4 ⋅ 5TA-00/DENSO Electrical ACM33221 M06/MATSUSHITA Definition of Units General Torque SpecificationsTorque Mkg Ftlb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 16 mm 130 Lubrication Diagrams Spec Cable Routing Diagram Spec Spec Spec Spec Spec Insp ADJ Maintenance Intervals Shift FORK, Shift CAM, Guide BAR Marked For USA General Inspection and Maintenance PRE-OPERATION Inspection and Maintenance Do not remove the radiator cap when the engine is hot Coolant ReplacementEngine Coolant Level Inspection Coolant Replacement Fill Radiator Engine To specified level Radiator CAP Inspection Radiator CAP Opening Pressure 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 Throttle Cable Adjustment Clutch Adjustment Hot starter lever free play adjustment steps HOT Starter Lever AdjustmentThrottle Lubrication Hot starter lever free play a 3 ~ 6 mm 0.12 ~ 0.24 AIR Filter Cleaning AIR Filter Cleaning Insp ADJ Engine OIL Level Inspection Engine OIL Level Inspection Recommended oil When the oil tank is empty, never start the engineRecommended engine oil classi- fication API Standard Engine OIL Replacement Engine OIL Replacement Oil filter cover 10 Nm 1.0 m kg, 7.2 ft lb Replacement steps Pilot Screw Adjustment Pilot Screw Adjustment Idle Speed Adjustment Adjustment stepsValve Clearance Adjustment Valve Clearance Adjustment Pad range Pad Availability Increments 20 mm Mm increments40 mm Last digit of pad Rounded value ExampleBolt camshaft cap 10 Nm 1.0 m kg, 7.2 ft lb Insp ADJ Exhaust Intake Spark Arrester Cleaning For USA CHASSIS/BRAKE System AIR Bleeding ChassisBrake System AIR Bleeding Front Brake Adjustment Front Brake AdjustmentBrake lever position adjustment steps Locknut Nm 0.5 m kg, 3.6 ft lb Front Brake PAD Inspection and Replacement Rear Brake Adjustment Front Brake PAD Inspection and Replacement Do not reuse the drained brake fluidBleed 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 0.04 Pad pin 18 Nm 1.8 m kg, 13 ft lb Brake Fluid Level Inspection Rear Brake PAD Insulator Inspection Sprockets Inspection Sprockets INSPECTION/DRIVE Chain InspectionDrive Chain Inspection Drive chain length 10 links Limit 150.1 mm 5.91 Drive Chain Inspection Drive Chain Slack Adjustment Drive Chain Slack AdjustmentDrive chain slack adjustment steps Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0 Axle nut 125 Nm 12.5 m kg, 90 ft lb Front Fork OIL Seal and Dust Seal CleaningLocknut 16 Nm 1.6 m kg, 11 ft lb Front Fork Inspection Front Fork Internal Pressure Relieving Front Fork Rebound Damping Force Adjustment Standard position 10 clicks out Clicks out Front Fork Compression Damping Force Adjustment Rear Shock Absorber Inspection Rear Shock Absorber Inspection Rear Shock Absorber Spring Preload Adjustment 246 mm 9.69 240.5 ~ 258.5 mm47 ~ 10.18 Standard position About 9 clicks out *About 10 clicks out Rear Shock Absorber Rebound Damping Force Adjustment Standard position About 6 clicks out *About 13 clicks out Rear Shock Absorber LOW Compression Damping Force Adjustment EC36d000 Standard tire pressure KPa 1.0 kgf/cm2, 15 psi Tire Pressure CheckSpokes Inspection and Tightening Wheel Inspection Steering Head Inspection Adjustment Steering Head Inspection and AdjustmentSteering ring nut adjustment steps Ring nut wrench YU-33975/90890-01403 Cautio N Lubrication Lubrication Electrical ELECTRICAL/SPARK Plug InspectionSpark Plug Inspection Spark plug gap ~ 0.8 mm 0.028 ~ 0.031 Ignition Timing Check Ignition Timing Check Battery Inspection and Charging Battery Inspection and ChargingKeep Batteries and Electrolyte OUT of Reach of Children First AID in Case of Bodily Contact External Measurement steps Example Do not quick charge a battery Insp ADJ Charging method using a variable voltage charger Charging method using a constant voltage charger First, connect the positive lead 1, then the negative lead Fuse InspectionRecommended lubricant Lithium soap base grease Fuse Inspection Replacing the Headlight Bulbs Items Amperage ’ty RatingReplacing the Headlight Bulbs Adjusting the Headlight Beams Adjusting the Headlight Beams SEAT, Fuel Tank and Side Covers Removal SEAT, Fuel Tank and Side Covers Side cover Removal Points Exhaust Pipe Silencer Removal Exhaust Pipe and Silencer Exhaust pipe and silencer Assembly and Installation Exhaust pipe and silencer Radiator Removal Radiator Assembly and Installation Radiator Handling NoteRadiator Install Radiator breather hose Radiator right Carburetor Removal Carburetor Carburetor Disassembly Carburetor Disassembly ENG Carburetor Pilot screw Throttle valve Needle valveJet needle Standard clip position No.4 Groove Measurement and adjustment steps FloatStarter plunger Assembly and Installation Carburetor Accelerator pumpAir cut valve ENG ENG Pilot screw 4 turns out example 2 turns out example ENG Carburetor installation Accelerator pump timing adjustment Adjustment stepsCarburetor ENG Throttle valve height Mm 0.122 Tighten Screw air cleaner joint Camshafts Cylinder Head CoverCylinder 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 Installation steps Assembly and InstallationDecompression system Timing chain tensioner Bolt camshaft cap CA U TI on Camshafts ENG Bolt timing chain tensionerTensioner cap bolt Cylinder Head Removal Cylinder Head Cylinder head Bolts cylinder head 1st 30 Nm 3.0 m kg, 22 ft lb 2nd Bolts cylinder head20 Nm 2.0 m kg, 14 ft lb Final Valves and Valve Springs Removal Valves and Valve Springs Valve spring compressor YM-4019/90890-04019 Valve ENG Runout limit 01 mm 0.0004 Lapping steps Valve spring Combination Cylinder head mark Valve lifter mark Color Combination of cylinder head and valve lifterYellow Black CA UT ION Cylinder and Piston Removal Cylinder and Piston Piston pin puller YU-1304/90890-01304 PistonDo not use a hammer to drive the piston pin out Piston ring Cylinder and piston 05 mm 0.002 Cylinder bore C 95.00 ~ 95.01 mm 7402 ~ 3.74062nd step Piston size P Standard 2nd ring 020 ~ 0.055 mm 12 mm 0008 ~ 0.0022 End gap Standard Limit20 ~ 0.50 mm 01 ~ 0.02 Inside diameter piston 18.004 ~ 18.015 mm 0.7088 ~ 0.7093 Piston pin Cylinder Clutch Removal Clutch ENG Clutch boss Clutch housing and bossClutch holding tool YM-91042/90890-04086 Primary driven gear Clutch plate Friction plateWarp limit Mm 0.004 Push lever Push rod Clutch Assembly and Installation Push lever ENG 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 Oil seal Impeller shaft Bearing Crankcase cover right Kick crank Water pump housing Oil filter Balancer Removal Balancer Balancer Balancer drive gear and balancer driven gear Balancer, balancer drive gear and balancer driven gear OIL Pump OIL Pump Removal and DIS Assembly ENG Oil pump Assembly and Installation Oil pump Bolt oil pump assembly L = 25 mm 0.98 Kick Axle and Shift Shaft Removal Kick Axle and Shift Shaft ENG Shift guide and shift lever assembly Kick axle assemblySegment Kick axle and ratchet wheel Assembly and Installation Segment Shift shaftStopper lever Install Torsion spring Stopper lever Bolt stopper lever EC4C5301 Kick idle gear AC Magneto and Stator Removal AC Magneto and Starter Clutch ENG Rotor puller YM-04141/90890-04141 RotorAC magneto Woodruff key Starter clutch Assembly and Installation AC magneto and starter clutch Quick 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 Removal ENG ENG Engine removal Drive sprocket Brake pedal Assembly and Installation Engine installation Install Ring 1 New Dowel pin Oil hose Bolt oil hose Crankcase Separation Crankcase and Crankshaft ENG Crankcase Bearing Removal Crankcase Bearing Separation steps Crankcase Crankshaft Crankcase separating tool YU-1135-A/90890-01135Timing chain and timing chain guide Oil delivery pipe Assembly and Installation Crankshaft bearing Quick gasket ACC-QUICK-GS-KT Yamaha Bond No Do not use a hammer to drive in the crank- shaft Bolt crankcase TRANSMISSION, Shift CAM and Shift Fork TRANSMISSION, Shift CAM and Shift ForkTRANSMISSION, Shift CAM Shift Fork Removal Gears Shift fork, shaft cam and transmission Shift fork, shift cam and segment Assembly and Installation Transmission ENG ENG Front Wheel and Rear Wheel Front Wheel and Rear Wheel ChasFront Wheel Front Wheel Removal Rear Wheel Removal Rear Wheel Rear wheel Wheel bearing if necessaryWheel Wheel axle bending limit 0.5 mm 0.020 Wheel axleDo not attempt to straighten a bent axle Brake disc Front wheel Caacuhtutionng 105 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 Front Brake and Rear Brake ChasFront Brake Front Brake Removal Rear Brake Removal Rear Brake Caliper Disassembly Caliper Disassembly Master Cylinder Disas Sembly Master Cylinder Disassembly Caliper piston Brake fluid Piston seal kit Master cylinderUse only new brake fluid Brake hose Caliper Front caliper Always use new piston seals and dust seals Rear caliper Always use new copper washers Master cylinder kit Front master cylinder Rear master cylinder Caauchtutionng Front brake hose Cauachttuniong Install Brake hose holder Screw brake hose holder Rear Diaphragm Master cylinder cap Bolt master cylinder cap Front Fork Chas Front ForkFront Fork Removal Front Fork Disassembly Front Fork Disassembly Cap bolt Take care not to scratch the inner tube Inner tubeOil seal removal steps Damper rod Fork spring Base valveInner tube bending limit 0.2 mm 0.008 Outer tube Assembly 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 Front fork top end standard a Zero mm Zero Installation Tighten Pinch bolt handle crown Handlebar Chas HandlebarHandlebar Removal Handlebar Grip Assembly and Installation Handlebar Install Cover grip cap Cover throttle cable cap Hot starter lever holder Bolt hot starter lever holder Handlebar Chas Steering Chas SteeringSteering Removal Steering Chas Bearing lower Ring nutTake care not to damage the steering shaft thread Ball race Under bracket Bearing and ball race Install Plain washer Ring nut Install Trip meter Bolt trip meter Swingarm Chas SwingarmSwingarm Removal Swingarm Disassembly Swingarm Disassembly Relay arm Swingarm Bearing and oil seal Connecting rod Installed depth of bearings a 5 mm 0.20 Swingarm Installed depth of bearings a 5 mm 0.20 80 Nm 8.0 m · kg, 58 ft · lb Tighten Nut relay arm Bolt support cover r= 10 mm 0.39 Rear Shock Absorber Chas Rear Shock AbsorberRear Shock Absorber Removal Rear Shock Absorber Chas Rear Shock Absorber Chas EC586000 Rear shock absorber Spring rear shock absorber Installed depth of the bearing a 4 mm 0.16 Adjustment Spring length installed a Standard Extent Bolt rear frame lower Rear Shock Absorber Chas Electrical Components and Wiring Diagram Wiring DiagramColor Code Function of Component MAP-CONTROLLED CDI Unit Inspection Steps Ignition System Spark GAP Test Ignition System Elec +COUPLERS, Leads and Ignition Coil Connection Inspection Engine Stop Button Inspection Main Switch Inspection OFFIgnition Coil Inspection Neutral Switch Inspection AC Magneto InspectionCDI Unit Inspection Starting Circuit CUT-OFF System Operation Electric Starting System Inspection Steps Starter Motor Operation Couplers and Leads Connection InspectionStarting Circuit CUT-OFF Relay Inspection Tor position Clutch Switch Inspection Starter Relay InspectionPull Free Start Switch Inspection Remove the diode from wire harnessElectric Starting System Elec + Diode Inspection Starter Motor Starter Motor RemovalStarter Motor Disassem BLY Elec Inspection and Repair Min. commutator diameter 16.6 mm 0.65Mica undercut 1.5 mm 0.06 Assembly Be careful not to damage the brush during installationMin. brush length Mm 0.14 New Charging System Tester + lead → Red lead Tester lead → Black lead Charging Voltage InspectionDCV-20 000 r/min TPS Throttle Position Sensor System TPS Coil Inspection TPS Throttle Position Sensor System Elec + Tester + lead → Yellow lead Tester lead → Black lead TPS Replacement and Adjustment DCV 58 ~ 0.78 TPS Input Voltage Inspection Tester + lead → Blue lead 1 Tester lead → Black/Blue lead~ 6 DCV-20 Lighting System Tester + lead → Yellow lead Tester lead → Blue lead Lights Switch InspectionNo continuous while being → Replace RECTIFIER/REGULATOR Inspection Carburetor setting Setting Humidity Setting T U N Effects of the setting parts on the throttle valve openingMain system Pilot system Main jet adjustmentStandard main jet #150 #160 Effects of changing the main jet reference Pilot screw adjustment Effects of adjusting the pilot screw referenceStandard pilot Screw position Example Effects of adjusting the pilot jet reference Pilot jet adjustmentJet needle groove position adjustment Standard pilot jet #45 #48 Standard jet needle Jet needle adjustmentObdut Obduq Effects of changing the jet needle reference #DUS STD#DUV #DUW Examples of carburetor setting depending on symptom Standard secondary reduction ratio 50/14 Selection of the secondary reduction ratio Sprocket 9383E-14215 5NG-17460-00For CDN, EUROPE, AUS, NZ and ZA Size Part number Change in level and characteristics of fork oil Front fork setting Setting of spring after replacement Spring preload adjustment Setting Spring Part NumberMark Rate Rear suspension setting Choosing set lengthStandard ﬁgure 90 ~ 100 mm 3.5 ~ 3.9 EC72G001 Setting Rear shock absorber setting parts Adjustment bSpring Free Extent Suspension setting One passenger is astride seat Printed on Recycled Paper Shingai Iwata Shizuoka Japan