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Yamaha WR45OFR service manual Front Brake and Rear Brake Chas, Front Brake Removal

Models: WR45OFR

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FRONT BRAKE AND REAR BRAKE CHAS

EC5A0000

FRONT BRAKE AND REAR BRAKE

EC5A8000

FRONT BRAKE

Extent of removal:													1 Brake hose removal		2 Caliper removal
													3 Master cylinder removal

	Extent of removal											Order	Part name	Q’ty			Remarks

													FRONT BRAKE REMOVAL
													FRONT BRAKE REMOVAL			WARNING
Preparation for removal													Hold the machine by placing the			WARNING
Preparation for removal													Hold the machine by placing the			Support the machine securely so there is no
													suitable stand under the engine.			Support the machine securely so there is no
													suitable stand under the engine.			danger of it falling over.

													Drain the brake fluid.			Refer to “REMOVAL POINTS”.

												1	Hose cover	1

				2
				2								2	Brake hose holder	1
												2	Brake hose holder	1
												3	Bolt (brake hose holder)	2		Only loosening.
	1											3	Bolt (brake hose holder)	2		Only loosening.
							3					4	Union bolt	2
												5	Brake hose	1
												6	Pad pin plug	1		Remove when loosening the pad pin.
				2								6	Pad pin plug	1		Remove when loosening the pad pin.
												7	Pad pin	1		Loosen when disassembling the caliper.
												8	Caliper	1
												9	Brake lever	1
												9	Brake lever	1
												10	Master cylinder bracket	1
								3				10	Master cylinder bracket	1
												11	Master cylinder	1
												11	Master cylinder	1
													5 - 11

Image 236

Yamaha WR45OFR service manual Front Brake and Rear Brake Chas, Front Brake Removal

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 OrderProperly Secure the Machine Before Transporting IT Gasoline can Cause InjuryPark the Machine Carefully Turn OFF the Engine 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 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 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 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 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 AdjustmentValve 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 ExhaustSpark Arrester Cleaning For USA Brake System AIR Bleeding CHASSIS/BRAKE System AIR BleedingChassis 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 ReplacementBleed screw Nm 0.6 m kg, 4.3 ft lb Front Brake PAD Inspection and ReplacementDo not reuse the drained brake fluid 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 Inspection47 ~ 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 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 InspectionReplacing the Headlight Bulbs Replacing the Headlight BulbsItems Amperage ’ty Rating 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 RemovalRadiator Assembly and Installation RadiatorHandling Note Install Radiator breather hose Radiator right Carburetor Carburetor RemovalCarburetor Disassembly Carburetor DisassemblyENG Pilot screw CarburetorNeedle valve Throttle valveJet needle Standard clip position No.4 GrooveStarter 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 Accelerator pump timing adjustment Adjustment steps Carburetor installationCarburetor ENG Throttle valve height Mm 0.122Tighten 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 Assembly and Installation Installation stepsDecompression system Timing chain tensionerCA U TI on Bolt camshaft capTensioner cap bolt Camshafts ENGBolt timing chain tensioner 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 Standard20 ~ 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 ~ 0.7093Cylinder 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 Crankcase Cover Right Removal OIL FILTER, Water Pump and Crankcase Cover RightOIL FILTER, Water Pump and Crankcase Cover Right 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 wheelStopper 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 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 stepsTiming 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 NoBolt crankcase TRANSMISSION, Shift CAM Shift Fork Removal TRANSMISSION, Shift CAM and Shift ForkTRANSMISSION, Shift CAM and Shift Fork 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 Rear wheelWheel bearing if necessary 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 pistonUse only new brake fluid Piston seal kitMaster cylinder 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 Removal Front Fork ChasFront Fork 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 Removal Handlebar ChasHandlebar 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 Removal Steering ChasSteering 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 Removal Swingarm ChasSwingarm 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 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 absorberSpring length installed a Standard Extent AdjustmentBolt rear frame lower Rear Shock Absorber Chas Color Code Electrical Components and Wiring DiagramWiring Diagram MAP-CONTROLLED CDI Unit Function of ComponentIgnition System Inspection StepsIgnition System Elec + Spark GAP TestCOUPLERS, Leads and Ignition Coil Connection Inspection Engine Stop Button InspectionIgnition Coil Inspection Main Switch InspectionOFF CDI Unit Inspection Neutral Switch InspectionAC Magneto 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 positionPull Free Clutch Switch InspectionStarter Relay Inspection Remove the diode from wire harness Start Switch InspectionElectric Starting System Elec + Diode InspectionStarter 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 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 DCV~ 6 DCV-20 TPS Input Voltage InspectionTester + lead → Blue lead 1 Tester lead → Black/Blue lead Lighting System Lights Switch Inspection Tester + lead → Yellow lead Tester lead → Blue leadNo continuous while being → Replace RECTIFIER/REGULATOR InspectionSetting Carburetor settingHumidity Main system Setting T U NEffects of the setting parts on the throttle valve opening Main jet adjustment Pilot systemStandard main jet #150 #160 Effects of changing the main jet referenceStandard pilot Screw position Example Pilot screw adjustmentEffects of adjusting the pilot screw reference 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 RateStandard 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