Eng | Yamaha WR45OFR specification

ENGINE REMOVAL

ENG

Extent of removal:					1 Engine removal

Extent of removal				Order	Part name	Q’ty		Remarks

					Crankcase cover (left)			Refer to “AC MAGNETO AND
								STARTER CLUTCH” section for remov-
								ing the starter motor lead.
					Disconnect the starter motor			Refer to “ELECTRIC STARTING SYS-
					lead.			TEM” section in the CHAPTER 6.
					Negative battery lead			Disconnect at the starter motor side.

				1	Engine skid plate (front)	1
				1	Engine skid plate (front)	1
				2	Neutral switch	1
				3	Oil hose	2
				4	Chain cover	1
				5	Nut (drive sprocket)	1
	1			5	Nut (drive sprocket)	1
	1			6	Lock washer	1		Refer to “REMOVAL POINTS”.
				6	Lock washer	1		Refer to “REMOVAL POINTS”.
				7	Drive sprocket	1
				7	Drive sprocket	1
				8	Clip	1
				9	Bolt (brake pedal)	1
				10	Brake pedal	1
				10	Brake pedal	1

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Yamaha WR45OFR service manual Eng

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 Model Label Machine IdentificationVehicle Identification Number Engine Serial Number Important Information Preparation for Removal and Disassembly Bearings and OIL Seals ALL Replacement PartsLock WASHERS/PLATES and Cotter Pins GASKETS, OIL Seals and O-RINGS Circlips Checking of Connection Special Tools Part number Tool name/How to use Illustration GEN Info ACC-QUICK-GS-KT Control Functions Main SwitchMain switch indicator light Start Switch Throttle Grip Clutch LeverShift Pedal Kickstarter HOT Starter Lever Rear Brake PedalFuel Cock Cold Starter Knob Nipple Wrench Lights SwitchValve Joint Spark Plug 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 PISTON, RING, VALVES, Camshafts and Gears BREAK-IN ProceduresCylinder and Crankshaft About one hour of break-in operation is necessary 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 Mkg Ftlb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 16 mm 130 General Torque SpecificationsDefinition of Units Torque 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 Coolant Level Inspection Coolant ReplacementDo not remove the radiator cap when the engine is hot Engine 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 a 3 ~ 6 mm 0.12 ~ 0.24 HOT Starter Lever AdjustmentHot starter lever free play adjustment steps Throttle Lubrication AIR Filter Cleaning AIR Filter Cleaning Insp ADJ Engine OIL Level Inspection Engine OIL Level Inspection API Standard When the oil tank is empty, never start the engineRecommended oil Recommended engine oil classi- fication 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 Locknut Nm 0.5 m kg, 3.6 ft lb Front Brake AdjustmentFront Brake Adjustment Brake lever position adjustment steps 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 Brake pad thickness a Standard Limit Mm 0.25 Mm 0.04 Rear Brake PAD Inspection and ReplacementRear Brake PAD Inspection and Replacement Pad pin plug Nm 0.3 m kg, 2.2 ft lb Pad pin 18 Nm 1.8 m kg, 13 ft lb Brake Fluid Level Inspection Rear Brake PAD Insulator Inspection Drive chain length 10 links Limit 150.1 mm 5.91 Sprockets INSPECTION/DRIVE Chain InspectionSprockets Inspection Drive Chain Inspection Drive Chain Inspection Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0 Drive Chain Slack AdjustmentDrive Chain Slack Adjustment Drive chain slack adjustment steps Front Fork Inspection Front Fork OIL Seal and Dust Seal CleaningAxle nut 125 Nm 12.5 m kg, 90 ft lb Locknut 16 Nm 1.6 m kg, 11 ft lb 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 Wheel Inspection Tire Pressure CheckStandard tire pressure KPa 1.0 kgf/cm2, 15 psi Spokes Inspection and Tightening Ring nut wrench YU-33975/90890-01403 Steering Head Inspection and AdjustmentSteering Head Inspection Adjustment Steering ring nut adjustment steps Cautio N Lubrication Lubrication Spark plug gap ~ 0.8 mm 0.028 ~ 0.031 ELECTRICAL/SPARK Plug InspectionElectrical Spark Plug Inspection Ignition Timing Check Ignition Timing Check First AID in Case of Bodily Contact External Battery Inspection and ChargingBattery Inspection and Charging Keep Batteries and Electrolyte OUT of Reach of Children 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 Fuse Inspection Fuse InspectionFirst, connect the positive lead 1, then the negative lead Recommended lubricant Lithium soap base grease 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 Standard clip position No.4 Groove Needle valveThrottle valve Jet needle 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 Throttle valve height Mm 0.122 Accelerator pump timing adjustment Adjustment stepsCarburetor installation Carburetor ENG 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 Timing chain tensioner Assembly and InstallationInstallation steps Decompression system 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 Final Bolts cylinder head2nd 20 Nm 2.0 m kg, 14 ft lb 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 Black Combination of cylinder head and valve lifterCombination Cylinder head mark Valve lifter mark Color Yellow CA UT ION Cylinder and Piston Removal Cylinder and Piston Cylinder and piston PistonPiston pin puller YU-1304/90890-01304 Do not use a hammer to drive the piston pin out Piston ring Piston size P Standard Cylinder bore C 95.00 ~ 95.01 mm 7402 ~ 3.740605 mm 0.002 2nd step 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 Primary driven gear Clutch housing and bossClutch boss Clutch holding tool YM-91042/90890-04086 Push rod Friction plateClutch plate Warp limit Mm 0.004 Push lever 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 Kick axle and ratchet wheel Kick axle assemblyShift guide and shift lever assembly Segment 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 Woodruff key RotorRotor puller YM-04141/90890-04141 AC magneto 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 Removal Front Wheel and Rear Wheel ChasFront Wheel and Rear Wheel Front Wheel Rear Wheel Removal Rear Wheel Rear wheel Wheel bearing if necessaryWheel Brake disc Wheel axleWheel axle bending limit 0.5 mm 0.020 Do not attempt to straighten a bent axle 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 Removal Front Brake and Rear Brake ChasFront Brake and Rear Brake Front Brake 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 Damper rod Inner tubeTake care not to scratch the inner tube Oil seal removal steps Outer tube Base valveFork spring Inner tube bending limit 0.2 mm 0.008 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 Ball race Ring nutBearing lower Take care not to damage the steering shaft thread 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 Engine Stop Button Inspection Ignition System Elec +Spark GAP Test COUPLERS, Leads and Ignition Coil Connection 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 Tor position Couplers and Leads Connection InspectionStarter Motor Operation Starting Circuit CUT-OFF Relay Inspection Clutch Switch Inspection Starter Relay InspectionPull Free Diode Inspection Remove the diode from wire harnessStart Switch Inspection Electric Starting System Elec + 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 000 r/min Charging Voltage InspectionTester + lead → Red lead Tester lead → Black lead DCV-20 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 RECTIFIER/REGULATOR Inspection Lights Switch InspectionTester + lead → Yellow lead Tester lead → Blue lead No continuous while being → Replace Carburetor setting Setting Humidity Setting T U N Effects of the setting parts on the throttle valve openingMain system Effects of changing the main jet reference Main jet adjustmentPilot system Standard main jet #150 #160 Pilot screw adjustment Effects of adjusting the pilot screw referenceStandard pilot Screw position Example Standard pilot jet #45 #48 Pilot jet adjustmentEffects of adjusting the pilot jet reference Jet needle groove position adjustment Effects of changing the jet needle reference Jet needle adjustmentStandard jet needle Obdut Obduq #DUW STD#DUS #DUV Examples of carburetor setting depending on symptom Standard secondary reduction ratio 50/14 Selection of the secondary reduction ratio Sprocket Size Part number 5NG-17460-009383E-14215 For CDN, EUROPE, AUS, NZ and ZA Change in level and characteristics of fork oil Front fork setting Setting of spring after replacement Spring preload adjustment Setting Rate Part NumberSpring Mark 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