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Yamaha WR45OFR service manual Standard Lubrication chart

Models: WR45OFR

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MAINTENANCE SPECIFICATIONS		SPEC
Item	Standard
Lubrication chart:
Pressure feed		Oil tank
Splashed scavenge
	Camshaft
Cylinder head	Valve lifter
	Piston
Transmission gears
	Piston pin
Main axle
Oil filter	Crank pin
Drive axle
Check ball
Oil pump rotor 1
Oil pump rotor 2
Oil strainer
		Oil pan

2 - 10

Image 47

Yamaha WR45OFR service manual Standard Lubrication chart

Contents

WR450FR Page LIT-11626-16-43 WR450FRBy Yamaha Motor Corporation, U.S.A 1st Edition, October Introduction Page Always Maintain Your Machine in Proper Working Order Always Wear Protective ApparelProperly Secure the Machine Before Transporting IT Gasoline can Cause InjuryPark the Machine Carefully Turn OFF the Engine Weights of machines without fuel M. Machine WeightsFinding the Required Particularly Important InformationManual Format HOW to Read DescriptionsGEN 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 CoversTPS Throttle Position Sensor Electrical ComponentsDescription Description InfoModel Label Machine IdentificationVehicle Identification Number Engine Serial NumberImportant Information Preparation for Removal and DisassemblyBearings and OIL Seals ALL Replacement PartsLock WASHERS/PLATES and Cotter Pins GASKETS, OIL Seals and O-RINGSCirclips Checking of Connection Special Tools Part number Tool name/How to use IllustrationGEN Info ACC-QUICK-GS-KT Control Functions Main SwitchMain switch indicator light Start SwitchThrottle Grip Clutch LeverShift Pedal KickstarterHOT Starter Lever Rear Brake PedalFuel Cock Cold Starter KnobNipple Wrench Lights SwitchValve Joint Spark Plug 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 PISTON, RING, VALVES, Camshafts and Gears BREAK-IN ProceduresCylinder and Crankshaft About one hour of break-in operation is necessaryTORQUE-CHECK Points Cleaning Cleaning and StorageStorage 5TJ4 CDN, AUS, NZ, ZA General SpecificationsFCR MX39 CDI Engine Maintenance SpecificationsSeat 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 ChassisDID520VM/DAIDO Handle crown and outer tube Rear wheel axle and nut M4 ⋅ 5TA-00/DENSO ElectricalACM33221 M06/MATSUSHITA Mkg Ftlb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 16 mm 130 General Torque SpecificationsDefinition of Units TorqueLubrication Diagrams Spec Cable Routing Diagram Spec Spec Spec Spec Spec Insp ADJ Maintenance IntervalsShift FORK, Shift CAM, Guide BAR Marked For USA General Inspection and Maintenance PRE-OPERATION Inspection and MaintenanceCoolant Level Inspection Coolant ReplacementDo not remove the radiator cap when the engine is hot EngineCoolant 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 Throttle Cable Adjustment Clutch AdjustmentHot starter lever free play a 3 ~ 6 mm 0.12 ~ 0.24 HOT Starter Lever AdjustmentHot starter lever free play adjustment steps Throttle LubricationAIR Filter Cleaning AIR Filter CleaningInsp ADJ Engine OIL Level Inspection Engine OIL Level InspectionAPI Standard When the oil tank is empty, never start the engineRecommended oil Recommended engine oil classi- ficationEngine OIL Replacement Engine OIL ReplacementOil filter cover 10 Nm 1.0 m kg, 7.2 ft lb Replacement stepsPilot 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 Exhaust IntakeSpark Arrester Cleaning For USA Brake System AIR Bleeding CHASSIS/BRAKE System AIR BleedingChassis Locknut Nm 0.5 m kg, 3.6 ft lb Front Brake AdjustmentFront Brake Adjustment Brake lever position adjustment stepsFront Brake PAD Inspection and Replacement Rear Brake AdjustmentBleed screw Nm 0.6 m kg, 4.3 ft lb Front Brake PAD Inspection and ReplacementDo not reuse the drained brake fluid 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 lbPad pin 18 Nm 1.8 m kg, 13 ft lb Brake Fluid Level Inspection Rear Brake PAD Insulator InspectionDrive chain length 10 links Limit 150.1 mm 5.91 Sprockets INSPECTION/DRIVE Chain InspectionSprockets Inspection Drive Chain InspectionDrive Chain Inspection Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0 Drive Chain Slack AdjustmentDrive Chain Slack Adjustment Drive chain slack adjustment stepsFront 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 lbFront Fork Internal Pressure Relieving Front Fork Rebound Damping Force AdjustmentStandard position 10 clicks out Clicks out Front Fork Compression Damping Force AdjustmentRear Shock Absorber Inspection Rear Shock Absorber Inspection47 ~ 10.18 Rear Shock Absorber Spring Preload Adjustment246 mm 9.69 240.5 ~ 258.5 mm Standard position About 9 clicks out *About 10 clicks out Rear Shock Absorber Rebound Damping Force AdjustmentStandard position About 6 clicks out *About 13 clicks out Rear Shock Absorber LOW Compression Damping Force AdjustmentEC36d000 Wheel Inspection Tire Pressure CheckStandard tire pressure KPa 1.0 kgf/cm2, 15 psi Spokes Inspection and TighteningRing nut wrench YU-33975/90890-01403 Steering Head Inspection and AdjustmentSteering Head Inspection Adjustment Steering ring nut adjustment stepsCautio N Lubrication LubricationSpark plug gap ~ 0.8 mm 0.028 ~ 0.031 ELECTRICAL/SPARK Plug InspectionElectrical Spark Plug InspectionIgnition Timing Check Ignition Timing CheckFirst AID in Case of Bodily Contact External Battery Inspection and ChargingBattery Inspection and Charging Keep Batteries and Electrolyte OUT of Reach of ChildrenMeasurement steps Example Do not quick charge a batteryInsp 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 greaseReplacing the Headlight Bulbs Replacing the Headlight BulbsItems Amperage ’ty Rating Adjusting the Headlight Beams Adjusting the Headlight BeamsSEAT, Fuel Tank and Side Covers Removal SEAT, Fuel Tank and Side CoversSide cover Removal PointsExhaust Pipe Silencer Removal Exhaust Pipe and SilencerExhaust pipe and silencer Assembly and Installation Exhaust pipe and silencerRadiator Removal RadiatorRadiator Assembly and Installation RadiatorHandling Note Install Radiator breather hose Radiator right Carburetor Removal CarburetorCarburetor Disassembly Carburetor DisassemblyENG Carburetor Pilot screwStandard clip position No.4 Groove Needle valveThrottle valve Jet needleStarter 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 Throttle valve height Mm 0.122 Accelerator pump timing adjustment Adjustment stepsCarburetor installation Carburetor ENGTighten 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 Timing chain tensioner Assembly and InstallationInstallation steps Decompression systemBolt camshaft cap CA U TI onTensioner cap bolt Camshafts ENGBolt timing chain tensioner Cylinder Head Removal Cylinder HeadCylinder 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 lbValves and Valve Springs Removal Valves and Valve SpringsValve 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 YellowCA UT ION Cylinder and Piston Removal Cylinder and PistonCylinder and piston PistonPiston pin puller YU-1304/90890-01304 Do not use a hammer to drive the piston pin out Piston ringPiston size P Standard Cylinder bore C 95.00 ~ 95.01 mm 7402 ~ 3.740605 mm 0.002 2nd step20 ~ 0.50 mm 01 ~ 0.02 2nd ring 020 ~ 0.055 mm 12 mm 0008 ~ 0.0022End gap Standard Limit Inside diameter piston 18.004 ~ 18.015 mm 0.7088 ~ 0.7093 Piston pinCylinder Clutch Removal ClutchENG Primary driven gear Clutch housing and bossClutch boss Clutch holding tool YM-91042/90890-04086Push rod Friction plateClutch plate Warp limit Mm 0.004 Push leverClutch Assembly and Installation Push leverENG 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 Oil seal Impeller shaftBearing Crankcase cover right Kick crank Water pump housingOil filter Balancer Removal BalancerBalancer Balancer drive gear and balancer driven gearBalancer, balancer drive gear and balancer driven gear OIL Pump OIL Pump Removal and DIS AssemblyENG Oil pump Assembly and Installation Oil pumpBolt oil pump assembly L = 25 mm 0.98 Kick Axle and Shift Shaft Removal Kick Axle and Shift ShaftENG Kick axle and ratchet wheel Kick axle assemblyShift guide and shift lever assembly SegmentStopper lever Assembly and Installation SegmentShift shaft Install Torsion spring Stopper lever Bolt stopper lever EC4C5301 Kick idle gear AC Magneto and Stator Removal AC Magneto and Starter ClutchENG Woodruff key RotorRotor puller YM-04141/90890-04141 AC magnetoStarter clutch Assembly and Installation AC magneto and 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 Engine removal Drive sprocketBrake pedal Assembly and Installation Engine installationInstall Ring 1 New Dowel pin Oil hose Bolt oil hose Crankcase Separation Crankcase and CrankshaftENG Crankcase Bearing Removal Crankcase BearingSeparation steps CrankcaseTiming chain and timing chain guide CrankshaftCrankcase separating tool YU-1135-A/90890-01135 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- shaftBolt crankcase TRANSMISSION, Shift CAM Shift Fork Removal TRANSMISSION, Shift CAM and Shift ForkTRANSMISSION, Shift CAM and Shift Fork Gears Shift fork, shaft cam and transmissionShift fork, shift cam and segment Assembly and Installation TransmissionENG ENG Front Wheel Removal Front Wheel and Rear Wheel ChasFront Wheel and Rear Wheel Front WheelRear Wheel Removal Rear WheelWheel Rear wheelWheel bearing if necessary Brake disc Wheel axleWheel axle bending limit 0.5 mm 0.020 Do not attempt to straighten a bent axleFront wheel Caacuhtutionng105 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 BrakeRear Brake Removal Rear BrakeCaliper Disassembly Caliper DisassemblyMaster Cylinder Disas Sembly Master Cylinder DisassemblyCaliper piston Brake fluidUse only new brake fluid Piston seal kitMaster cylinder Brake hose CaliperFront caliper Always use new piston seals and dust sealsRear caliper Always use new copper washersMaster cylinder kit Front master cylinder Rear master cylinder CaauchtutionngFront 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 Damper rod Inner tubeTake care not to scratch the inner tube Oil seal removal stepsOuter tube Base valveFork spring Inner tube bending limit 0.2 mm 0.008Assembly 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 InstallationTighten Pinch bolt handle crown Handlebar Removal Handlebar ChasHandlebar Handlebar GripAssembly 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 Ball race Ring nutBearing lower Take care not to damage the steering shaft threadUnder bracket Bearing and ball raceInstall Plain washer Ring nut Install Trip meter Bolt trip meter Swingarm Removal Swingarm ChasSwingarm Swingarm Disassembly Swingarm DisassemblyRelay arm SwingarmBearing and oil seal Connecting rodInstalled depth of bearings a 5 mm 0.20 Swingarm Installed depth of bearings a 5 mm 0.2080 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 Spring rear shock absorber Installed depth of the bearing a 4 mm 0.16Adjustment Spring length installed a Standard ExtentBolt rear frame lower Rear Shock Absorber Chas Color Code Electrical Components and Wiring DiagramWiring Diagram Function of Component MAP-CONTROLLED CDI UnitInspection Steps Ignition SystemEngine Stop Button Inspection Ignition System Elec +Spark GAP Test COUPLERS, Leads and Ignition Coil Connection InspectionIgnition Coil Inspection Main Switch InspectionOFF CDI Unit Inspection Neutral Switch InspectionAC Magneto Inspection Starting Circuit CUT-OFF System Operation Electric Starting SystemInspection Steps Tor position Couplers and Leads Connection InspectionStarter Motor Operation Starting Circuit CUT-OFF Relay InspectionPull Free Clutch Switch InspectionStarter Relay Inspection Diode Inspection Remove the diode from wire harnessStart Switch Inspection Electric Starting System Elec +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 000 r/min Charging Voltage InspectionTester + lead → Red lead Tester lead → Black lead DCV-20TPS Throttle Position Sensor System TPS Coil Inspection TPS Throttle Position Sensor System Elec +Tester + lead → Yellow lead Tester lead → Black lead TPS Replacement and AdjustmentDCV 58 ~ 0.78~ 6 DCV-20 TPS Input Voltage InspectionTester + lead → Blue lead 1 Tester lead → Black/Blue lead Lighting System RECTIFIER/REGULATOR Inspection Lights Switch InspectionTester + lead → Yellow lead Tester lead → Blue lead No continuous while being → ReplaceCarburetor setting SettingHumidity Main system Setting T U NEffects of the setting parts on the throttle valve opening Effects of changing the main jet reference Main jet adjustmentPilot system Standard main jet #150 #160Standard pilot Screw position Example Pilot screw adjustmentEffects of adjusting the pilot screw reference Standard pilot jet #45 #48 Pilot jet adjustmentEffects of adjusting the pilot jet reference Jet needle groove position adjustmentEffects of changing the jet needle reference Jet needle adjustmentStandard jet needle Obdut Obduq#DUW STD#DUS #DUVExamples of carburetor setting depending on symptom Standard secondary reduction ratio 50/14 Selection of the secondary reduction ratio SprocketSize Part number 5NG-17460-009383E-14215 For CDN, EUROPE, AUS, NZ and ZAChange in level and characteristics of fork oil Front fork settingSetting of spring after replacement Spring preload adjustmentSetting Rate Part NumberSpring MarkStandard 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