Yamaha WR45OFR specification

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Yamaha WR45OFR service manual

Contents

WR450FR Page LIT-11626-16-43 WR450FRBy Yamaha Motor Corporation, U.S.A 1st Edition, October Introduction Page Always Wear Protective Apparel Always Maintain Your Machine in Proper Working Order Properly Secure the Machine Before Transporting IT Gasoline can Cause InjuryPark the Machine Carefully Turn OFF the Engine M. Machine Weights Weights of machines without fuel Particularly Important Information Finding the Required HOW to Read Descriptions Manual Format GEN 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 Brake Electrical Components TPS Throttle Position Sensor Description Info Description Engine Serial Number Machine IdentificationVehicle Identification Number Model Label Preparation for Removal and Disassembly Important Information GASKETS, OIL Seals and O-RINGS ALL Replacement PartsLock WASHERS/PLATES and Cotter Pins Bearings and OIL Seals Circlips Checking of Connection Part number Tool name/How to use Illustration Special Tools GEN Info ACC-QUICK-GS-KT Start Switch Main SwitchMain switch indicator light Control Functions Kickstarter Clutch LeverShift Pedal Throttle Grip Cold Starter Knob Rear Brake PedalFuel Cock HOT Starter Lever Spark Plug Wrench Lights SwitchValve Joint Nipple Wrench Fuel Starting a Cold Engine AIR Filter MaintenanceStarting and BREAK-IN Do not warm up the engine for extended periods of time Engine fails to start Starting a Warm EngineRestarting an engine after a fall About one hour of break-in operation is necessary BREAK-IN ProceduresCylinder and Crankshaft PISTON, RING, VALVES, Camshafts and Gears TORQUE-CHECK Points Cleaning and Storage Cleaning Storage General Specifications 5TJ4 CDN, AUS, NZ, ZA FCR MX39 CDI Maintenance Specifications Engine 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 Chassis USA, CDN Europe AUS, NZ, ZA DID520VM/DAIDO Handle crown and outer tube Rear wheel axle and nut M4 ⋅ Electrical 5TA-00/DENSO ACM33221 M06/MATSUSHITA Torque General Torque SpecificationsDefinition of Units 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 Maintenance Intervals Insp ADJ Shift FORK, Shift CAM, Guide BAR Marked For USA PRE-OPERATION Inspection and Maintenance General Inspection and Maintenance Engine Coolant ReplacementDo not remove the radiator cap when the engine is hot Coolant Level Inspection Coolant Replacement Fill Radiator Engine To specified level Radiator cap opening pressure 110 kPa 1.1 kg/cm2, 15.6 psi Radiator CAP InspectionRadiator CAP Opening Pressure Inspection Standard pressure KPa 1.8 kg/cm2, 25.6 psi Cooling System InspectionCooling System Inspection Clutch Adjustment Throttle Cable Adjustment Throttle Lubrication HOT Starter Lever AdjustmentHot starter lever free play adjustment steps 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 engine oil classi- fication When the oil tank is empty, never start the engineRecommended oil API Standard Engine OIL Replacement Engine OIL Replacement Replacement steps Oil filter cover 10 Nm 1.0 m kg, 7.2 ft lb Pilot Screw Adjustment Pilot Screw Adjustment Valve Clearance Adjustment Idle Speed AdjustmentAdjustment steps Valve Clearance Adjustment 40 mm Pad range Pad Availability Increments 20 mmMm increments Bolt camshaft cap 10 Nm 1.0 m kg, 7.2 ft lb Last digit of pad Rounded valueExample Insp ADJ Intake Exhaust Spark Arrester Cleaning For USA Brake System AIR Bleeding CHASSIS/BRAKE System AIR BleedingChassis Brake lever position adjustment steps Front Brake AdjustmentFront Brake Adjustment Locknut Nm 0.5 m kg, 3.6 ft lb Rear Brake Adjustment Front Brake PAD Inspection and Replacement Bleed screw Nm 0.6 m kg, 4.3 ft lb Front Brake PAD Inspection and ReplacementDo not reuse the drained brake fluid Pad pin plug Nm 0.3 m kg, 2.2 ft lb Rear Brake PAD Inspection and ReplacementRear Brake PAD Inspection and Replacement Brake pad thickness a Standard Limit Mm 0.25 Mm 0.04 Pad pin 18 Nm 1.8 m kg, 13 ft lb Rear Brake PAD Insulator Inspection Brake Fluid Level Inspection Drive Chain Inspection Sprockets INSPECTION/DRIVE Chain InspectionSprockets Inspection Drive chain length 10 links Limit 150.1 mm 5.91 Drive Chain Inspection Drive chain slack adjustment steps Drive Chain Slack AdjustmentDrive Chain Slack Adjustment Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0 Locknut 16 Nm 1.6 m kg, 11 ft lb Front Fork OIL Seal and Dust Seal CleaningAxle nut 125 Nm 12.5 m kg, 90 ft lb Front Fork Inspection Front Fork Rebound Damping Force Adjustment Front Fork Internal Pressure Relieving Front Fork Compression Damping Force Adjustment Standard position 10 clicks out Clicks out Rear Shock Absorber Inspection Rear Shock Absorber Inspection 47 ~ 10.18 Rear Shock Absorber Spring Preload Adjustment246 mm 9.69 240.5 ~ 258.5 mm Rear Shock Absorber Rebound Damping Force Adjustment Standard position About 9 clicks out *About 10 clicks out Rear Shock Absorber LOW Compression Damping Force Adjustment Standard position About 6 clicks out *About 13 clicks out EC36d000 Spokes Inspection and Tightening Tire Pressure CheckStandard tire pressure KPa 1.0 kgf/cm2, 15 psi Wheel Inspection Steering ring nut adjustment steps Steering Head Inspection and AdjustmentSteering Head Inspection Adjustment Ring nut wrench YU-33975/90890-01403 Cautio N Lubrication Lubrication Spark Plug Inspection ELECTRICAL/SPARK Plug InspectionElectrical Spark plug gap ~ 0.8 mm 0.028 ~ 0.031 Ignition Timing Check Ignition Timing Check Keep Batteries and Electrolyte OUT of Reach of Children Battery Inspection and ChargingBattery Inspection and Charging First AID in Case of Bodily Contact External Measurement steps Do not quick charge a battery Example Insp ADJ Charging method using a variable voltage charger Charging method using a constant voltage charger Recommended lubricant Lithium soap base grease Fuse InspectionFirst, connect the positive lead 1, then the negative lead Fuse Inspection Replacing the Headlight Bulbs Replacing the Headlight BulbsItems Amperage ’ty Rating Adjusting the Headlight Beams Adjusting the Headlight Beams SEAT, Fuel Tank and Side Covers SEAT, Fuel Tank and Side Covers Removal Removal Points Side cover Exhaust Pipe and Silencer Exhaust Pipe Silencer Removal Assembly and Installation Exhaust pipe and silencer Exhaust pipe and silencer Radiator Radiator Removal Radiator Assembly and Installation RadiatorHandling Note Install Radiator breather hose Radiator right Carburetor Carburetor Removal Carburetor Disassembly Carburetor Disassembly ENG Pilot screw Carburetor Jet needle Needle valveThrottle valve Standard clip position No.4 Groove Starter plunger Measurement and adjustment stepsFloat Air cut valve Assembly and Installation CarburetorAccelerator pump ENG ENG Pilot screw 4 turns out example 2 turns out example ENG Carburetor ENG Accelerator pump timing adjustment Adjustment stepsCarburetor installation Throttle valve height Mm 0.122 Tighten Screw air cleaner joint Cylinder Head Cover Removal CamshaftsCylinder Head Cover 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 Decompression system Assembly and InstallationInstallation steps Timing chain tensioner CA U TI on Bolt camshaft cap Tensioner cap bolt Camshafts ENGBolt timing chain tensioner Cylinder Head Cylinder Head Removal Cylinder head Bolts cylinder head 1st 30 Nm 3.0 m kg, 22 ft lb 20 Nm 2.0 m kg, 14 ft lb Bolts cylinder head2nd Final Valves and Valve Springs Valves and Valve Springs Removal Valve spring compressor YM-4019/90890-04019 Valve ENG Runout limit 01 mm 0.0004 Lapping steps Valve spring Yellow Combination of cylinder head and valve lifterCombination Cylinder head mark Valve lifter mark Color Black CA UT ION Cylinder and Piston Cylinder and Piston Removal Do not use a hammer to drive the piston pin out Piston ring PistonPiston pin puller YU-1304/90890-01304 Cylinder and piston 2nd step Cylinder bore C 95.00 ~ 95.01 mm 7402 ~ 3.740605 mm 0.002 Piston size P Standard 20 ~ 0.50 mm 01 ~ 0.02 2nd ring 020 ~ 0.055 mm 12 mm 0008 ~ 0.0022End gap Standard Limit Piston pin Inside diameter piston 18.004 ~ 18.015 mm 0.7088 ~ 0.7093 Cylinder Clutch Clutch Removal ENG Clutch holding tool YM-91042/90890-04086 Clutch housing and bossClutch boss Primary driven gear Warp limit Mm 0.004 Push lever Friction plateClutch plate Push rod Assembly and Installation Push lever Clutch ENG Install Clutch spring Bolt clutch spring OIL FILTER, Water Pump Crankcase Cover Right Removal OIL FILTER, Water Pump and Crankcase Cover RightOIL FILTER, Water Pump and Crankcase Cover Right ENG Impeller shaft Oil seal Bearing Crankcase cover right Water pump housing Kick crank Oil filter Balancer Balancer Removal Balancer drive gear and balancer driven gear Balancer Balancer, balancer drive gear and balancer driven gear OIL Pump Removal and DIS Assembly OIL Pump ENG Assembly and Installation Oil pump Oil pump Bolt oil pump assembly L = 25 mm 0.98 Kick Axle and Shift Shaft Kick Axle and Shift Shaft Removal ENG Segment Kick axle assemblyShift guide and shift lever assembly Kick axle and ratchet wheel Stopper lever Assembly and Installation SegmentShift shaft Install Torsion spring Stopper lever Bolt stopper lever EC4C5301 Kick idle gear AC Magneto and Starter Clutch AC Magneto and Stator Removal ENG AC magneto RotorRotor puller YM-04141/90890-04141 Woodruff key Assembly and Installation AC magneto and starter clutch 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 Drive sprocket Engine removal Assembly and Installation Engine installation Brake pedal Install Ring 1 New Dowel pin Oil hose Bolt oil hose Crankcase and Crankshaft Crankcase Separation ENG Crankcase Bearing Crankcase Bearing Removal Crankcase Separation steps Timing chain and timing chain guide CrankshaftCrankcase separating tool YU-1135-A/90890-01135 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 No Bolt crankcase TRANSMISSION, Shift CAM Shift Fork Removal TRANSMISSION, Shift CAM and Shift ForkTRANSMISSION, Shift CAM and Shift Fork Shift fork, shaft cam and transmission Gears Assembly and Installation Transmission Shift fork, shift cam and segment ENG ENG Front Wheel Front Wheel and Rear Wheel ChasFront Wheel and Rear Wheel Front Wheel Removal Rear Wheel Rear Wheel Removal Wheel Rear wheelWheel bearing if necessary Do not attempt to straighten a bent axle Wheel axleWheel axle bending limit 0.5 mm 0.020 Brake disc Caacuhtutionng Front wheel 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 Front Brake and Rear Brake ChasFront Brake and Rear Brake Front Brake Removal Rear Brake Rear Brake Removal Caliper Disassembly Caliper Disassembly Master Cylinder Disassembly Master Cylinder Disas Sembly Brake fluid Caliper piston Use only new brake fluid Piston seal kitMaster cylinder Caliper Brake hose Always use new piston seals and dust seals Front caliper Always use new copper washers Rear caliper Master cylinder kit Front master cylinder Caauchtutionng Rear master cylinder Front brake hose Cauachttuniong Install Brake hose holder Screw brake hose holder Rear Diaphragm Master cylinder cap Bolt master cylinder cap Front Fork Removal Front Fork ChasFront Fork Front Fork Disassembly Front Fork Disassembly Cap bolt Oil seal removal steps Inner tubeTake care not to scratch the inner tube Damper rod Inner tube bending limit 0.2 mm 0.008 Base valveFork spring 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 Installation Front fork top end standard a Zero mm Zero Tighten Pinch bolt handle crown Handlebar Removal Handlebar ChasHandlebar Grip Handlebar Assembly and Installation Handlebar Install Cover grip cap Cover throttle cable cap Hot starter lever holder Bolt hot starter lever holder Handlebar Chas Steering Removal Steering ChasSteering Steering Chas Take care not to damage the steering shaft thread Ring nutBearing lower Ball race Bearing and ball race Under bracket Install Plain washer Ring nut Install Trip meter Bolt trip meter Swingarm Removal Swingarm ChasSwingarm Swingarm Disassembly Swingarm Disassembly Swingarm Relay arm Connecting rod Bearing and oil seal Installed depth of bearings a 5 mm 0.20 Installed depth of bearings a 5 mm 0.20 Swingarm 80 Nm 8.0 m · kg, 58 ft · lb Tighten Nut relay arm Bolt support cover r= 10 mm 0.39 Rear Shock Absorber Removal Rear Shock Absorber ChasRear Shock Absorber 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 absorber Spring length installed a Standard Extent Adjustment Bolt rear frame lower Rear Shock Absorber Chas Color Code Electrical Components and Wiring DiagramWiring Diagram MAP-CONTROLLED CDI Unit Function of Component Ignition System Inspection Steps COUPLERS, Leads and Ignition Coil Connection Inspection Ignition System Elec +Spark GAP Test Engine Stop Button Inspection Ignition Coil Inspection Main Switch InspectionOFF CDI Unit Inspection Neutral Switch InspectionAC Magneto Inspection Electric Starting System Starting Circuit CUT-OFF System Operation Inspection Steps Starting Circuit CUT-OFF Relay Inspection Couplers and Leads Connection InspectionStarter Motor Operation Tor position Pull Free Clutch Switch InspectionStarter Relay Inspection Electric Starting System Elec + Remove the diode from wire harnessStart Switch Inspection Diode Inspection Starter Motor Disassem BLY Starter MotorStarter Motor Removal Elec Mica undercut 1.5 mm 0.06 Inspection and RepairMin. commutator diameter 16.6 mm 0.65 Min. brush length Mm 0.14 AssemblyBe careful not to damage the brush during installation New Charging System DCV-20 Charging Voltage InspectionTester + lead → Red lead Tester lead → Black lead 000 r/min TPS Throttle Position Sensor System TPS Throttle Position Sensor System Elec + TPS Coil Inspection TPS Replacement and Adjustment Tester + lead → Yellow lead Tester lead → Black lead 58 ~ 0.78 DCV ~ 6 DCV-20 TPS Input Voltage InspectionTester + lead → Blue lead 1 Tester lead → Black/Blue lead Lighting System No continuous while being → Replace Lights Switch InspectionTester + lead → Yellow lead Tester lead → Blue lead RECTIFIER/REGULATOR Inspection Setting Carburetor setting Humidity Main system Setting T U NEffects of the setting parts on the throttle valve opening Standard main jet #150 #160 Main jet adjustmentPilot system Effects of changing the main jet reference Standard pilot Screw position Example Pilot screw adjustmentEffects of adjusting the pilot screw reference Jet needle groove position adjustment Pilot jet adjustmentEffects of adjusting the pilot jet reference Standard pilot jet #45 #48 Obdut Obduq Jet needle adjustmentStandard jet needle Effects of changing the jet needle reference #DUV STD#DUS #DUW Examples of carburetor setting depending on symptom Selection of the secondary reduction ratio Sprocket Standard secondary reduction ratio 50/14 For CDN, EUROPE, AUS, NZ and ZA 5NG-17460-009383E-14215 Size Part number Front fork setting Change in level and characteristics of fork oil Spring preload adjustment Setting of spring after replacement Setting Mark Part NumberSpring Rate Standard ﬁgure 90 ~ 100 mm 3.5 ~ 3.9 Rear suspension settingChoosing set length EC72G001 Setting Spring Free Extent Rear shock absorber setting partsAdjustment b Suspension setting One passenger is astride seat Printed on Recycled Paper Shingai Iwata Shizuoka Japan