Yamaha WR45OFR manual

PRINTED ON RECYCLED PAPER	YAMAHA MOTOR CO., LTD.	PRINTED IN JAPAN
	2500 SHINGAI IWATA SHIZUOKA JAPAN	2002.10-2.0⋅1 CR
	2500 SHINGAI IWATA SHIZUOKA JAPAN	(E)
		(E)

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Yamaha WR45OFR service manual Printed on Recycled Paper Shingai Iwata Shizuoka Japan

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 Order Park the Machine Carefully Turn OFF the Engine Gasoline can Cause InjuryProperly Secure the Machine Before Transporting IT 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 Machine Identification Vehicle Identification NumberEngine Serial Number Model Label Preparation for Removal and Disassembly Important Information ALL Replacement Parts Lock WASHERS/PLATES and Cotter PinsGASKETS, OIL Seals and O-RINGS Bearings and OIL Seals Circlips Checking of Connection Part number Tool name/How to use Illustration Special Tools GEN Info ACC-QUICK-GS-KT Main Switch Main switch indicator lightStart Switch Control Functions Clutch Lever Shift PedalKickstarter Throttle Grip Rear Brake Pedal Fuel CockCold Starter Knob HOT Starter Lever Lights Switch Valve JointSpark Plug Wrench Nipple Wrench Fuel 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 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 General Torque Specifications Definition of UnitsTorque 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 Coolant Replacement Do not remove the radiator cap when the engine is hotEngine Coolant Level Inspection Coolant 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 Adjustment HOT Starter Lever Adjustment Hot starter lever free play adjustment stepsThrottle 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 When the oil tank is empty, never start the engine Recommended oilRecommended engine oil classi- fication 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 Adjustment 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 Exhaust Spark 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 lb Rear Brake Adjustment Front Brake PAD Inspection and Replacement Do 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 0.04 Pad pin 18 Nm 1.8 m kg, 13 ft lb Rear Brake PAD Insulator Inspection Brake Fluid Level Inspection Sprockets INSPECTION/DRIVE Chain Inspection Sprockets 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 Front 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 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 246 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 out Rear Shock Absorber LOW Compression Damping Force Adjustment Standard position About 6 clicks out *About 13 clicks out EC36d000 Tire Pressure Check Standard tire pressure KPa 1.0 kgf/cm2, 15 psiSpokes Inspection and Tightening Wheel Inspection Steering Head Inspection and Adjustment Steering Head Inspection AdjustmentSteering ring nut adjustment steps Ring nut wrench YU-33975/90890-01403 Cautio N Lubrication Lubrication ELECTRICAL/SPARK Plug Inspection ElectricalSpark 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 Do not quick charge a battery Example Insp 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 Inspection Items Amperage ’ty Rating Replacing the Headlight BulbsReplacing the Headlight Bulbs 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 Handling Note Assembly and Installation RadiatorRadiator Install Radiator breather hose Radiator right Carburetor Carburetor Removal Carburetor Disassembly Carburetor Disassembly ENG Pilot screw Carburetor Needle valve Throttle valveJet needle Standard clip position No.4 Groove Float 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 0.122 Tighten 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 tensioner CA U TI on Bolt camshaft cap Bolt timing chain tensioner Camshafts ENGTensioner cap bolt Cylinder Head Cylinder Head Removal Cylinder 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 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 Combination of cylinder head and valve lifter Combination Cylinder head mark Valve lifter mark ColorYellow Black CA UT ION Cylinder and Piston Cylinder and Piston Removal Piston Piston pin puller YU-1304/90890-01304Do not use a hammer to drive the piston pin out Piston ring Cylinder and piston Cylinder bore C 95.00 ~ 95.01 mm 7402 ~ 3.7406 05 mm 0.0022nd step Piston size P Standard End 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 ~ 0.7093 Cylinder Clutch Clutch Removal ENG Clutch housing and boss Clutch bossClutch holding tool YM-91042/90890-04086 Primary driven gear Friction plate Clutch plateWarp limit Mm 0.004 Push lever Push rod Assembly and Installation Push lever Clutch 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 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 Kick axle assembly Shift guide and shift lever assemblySegment Kick axle and ratchet wheel Shift 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 Removal ENG Rotor Rotor puller YM-04141/90890-04141AC magneto 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 Crankcase 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 No Bolt crankcase TRANSMISSION, Shift CAM and Shift Fork TRANSMISSION, Shift CAM and Shift ForkTRANSMISSION, Shift CAM Shift Fork Removal Shift fork, shaft cam and transmission Gears Assembly and Installation Transmission Shift fork, shift cam and segment ENG ENG Front Wheel and Rear Wheel Chas Front Wheel and Rear WheelFront Wheel Front Wheel Removal Rear Wheel Rear Wheel Removal Wheel bearing if necessary Rear wheelWheel Wheel axle Wheel axle bending limit 0.5 mm 0.020Do not attempt to straighten a bent axle 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 and Rear Brake Chas Front Brake and Rear BrakeFront Brake Front Brake Removal Rear Brake Rear Brake Removal Caliper Disassembly Caliper Disassembly Master Cylinder Disassembly Master Cylinder Disas Sembly Brake fluid Caliper piston Master cylinder Piston seal kitUse only new brake fluid 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 Front Fork ChasFront Fork Removal Front Fork Disassembly Front Fork Disassembly Cap bolt Inner tube Take care not to scratch the inner tubeOil seal removal steps Damper rod Base valve Fork springInner 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 Installation Front fork top end standard a Zero mm Zero Tighten Pinch bolt handle crown Handlebar Handlebar ChasHandlebar Removal 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 Steering ChasSteering Removal Steering Chas Ring nut Bearing lowerTake care not to damage the steering shaft thread Ball race Bearing and ball race Under bracket Install Plain washer Ring nut Install Trip meter Bolt trip meter Swingarm Swingarm ChasSwingarm Removal 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 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 absorber Spring length installed a Standard Extent Adjustment Bolt rear frame lower Rear Shock Absorber Chas Wiring Diagram Electrical Components and Wiring DiagramColor Code MAP-CONTROLLED CDI Unit Function of Component Ignition System Inspection Steps Ignition System Elec + Spark GAP TestCOUPLERS, Leads and Ignition Coil Connection Inspection Engine Stop Button Inspection OFF Main Switch InspectionIgnition Coil Inspection AC Magneto Inspection Neutral Switch InspectionCDI Unit Inspection Electric Starting System Starting Circuit CUT-OFF System Operation Inspection Steps Couplers and Leads Connection Inspection Starter Motor OperationStarting Circuit CUT-OFF Relay Inspection Tor position Starter Relay Inspection Clutch Switch InspectionPull Free Remove the diode from wire harness Start Switch InspectionElectric Starting System Elec + Diode Inspection Starter 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/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 Tester + 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 Inspection Setting Carburetor setting Humidity 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 reference Effects 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 #48 Jet needle adjustment Standard jet needleObdut Obduq Effects of changing the jet needle reference STD #DUS#DUV #DUW Examples of carburetor setting depending on symptom Selection of the secondary reduction ratio Sprocket Standard secondary reduction ratio 50/14 5NG-17460-00 9383E-14215For CDN, EUROPE, AUS, NZ and ZA Size Part number Front fork setting Change in level and characteristics of fork oil Spring preload adjustment Setting of spring after replacement Setting Part Number SpringMark Rate Choosing 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