Yamaha WR450F(V) - User Manual

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5TJ-28199-43

WR450F(V)

OWNER’S SERVICE MANUAL

MANUEL D’ATELIER DU

PROPRIETAIRE

FAHRER- UND

WARTUNGS-HANDBUCH

MANUAL DE SERVICIO

DEL PROPIETARIO

PRINTED IN JAPAN

2005.06-3.5×1 CR

(E,F,G,S)

WR450F(V)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

Main Page

Introduction4
Important Notice6
F.I.M. Machine Weights10
Weights of Machines Without Fuel10
Description12
Renseignements Generaux13
How to Read Descriptions14
Illustrated Symbols16
Index18
Table of Contents20
General Information26
Description26
Allgemeine Angaben27
Machine Identification28
Vehicle Identification Number28
Engine Serial Number28
Model Label28
Identification de la Moto29
Important Information30
Preparation for Removal and Disassembly30
Informations Importantes31
Wichtige Informationen31
All Replacement Parts32
Gaskets, Oil Seals and O-Rings32
Lock Washers/Plates and Cotter Pins32
Bearings and Oil Seals32
Circlips34
Checking of Connection36
Verification des Connexions37
Special Tools38
Outils Speciaux41
Herramientas Especiales47
Control Functions50
Main Switch50
Main Switch Indicator Light50
“Engine Stop” Button50
Fonctions des Commandes51
Engine51
Moteur51
Motor51
Clutch Lever52
Shift Pedal52
Kickstarter52
Throttle Grip52
Bedienungselemente und Deren Funktion53
Funciones de Los Mandos53
Rear Brake Pedal54
Fuel Cock54
Cold Starter Knob54
Hot Starter Lever54
Sidestand56
Valve Joint56
Spark Plug Wrench56
Nipple Wrench56
Multi-Function Display58
Operation Buttons58
Screen Display58
Ecran Multifonction59
Basic Mode60
Changing Speedometer Display (for U.K.)60
Setting the Time60
Normal-Betriebsart61
Función Básica61
Mode de Base61
Ajuste de la Hora61
Uhr Stellen61
Changing Odometer and Tripmeter A/B62
Changeover to Basic Mode/Race Mode62
Changeover from BASIC MODE to RACE MODE62
Returning to BASIC MODE from RACE MODE64
Race Mode64
Putting Measurement on Standby64
Manual Start64
Correcting Tripmeter a68
Resetting Measurement Data68
Resetting Tripmeter a68
Resetting Tripmeter a (TRIP A) and Timer68
Function Diagram70
Fuel72
Carburant73
Starting and Break-In74
Starting a Cold Engine74
Air Filter Maintenance74
Puesta en Marcha y Rodaje75
Mise en Marche Et Rodage75
Starten und Einfahren75
Starting a Warm Engine78
Restarting an Engine after a Fall78
The Engine Fails to Start78
Break-In Procedures80
Torque-Check Points80
Torque-Check Points82
Points de Verification des Couples de Serrage83
Anzugsdrehmomente Kontrollieren84
Cleaning and Storage86
Limpieza y Almacenamiento87
Nettoyage Et Remisage87
Pflege und Lagerung87
Storage88
General Specifications90
Chassis91
Maintenance Specifications93
Lubrication Chart99
Electrical107
General Torque Specifications109
Definition of Units109
Caracteristiques Generales110
Caracteristiques D'entretien113
Caracteristiques Generales de Couple129
Definition des Unites129
Technische Daten130
Fahrwerk131
Allgemeine Technische Daten132
Allgemeine Anzugsmomente149
Especificaciones Generales150
Especificaciones de Mantenimiento153
Especificaciones Generales de Apriete169
Lubrication Diagrams170
Diagrammes de Lubrification171
Diagramas de Engrase171
Cable Routing Diagram174
Diagramme D'acheminement des Cables175
Kabelführungsdiagram Me175
Diagrama de Cableado175
Chassis176
Radiateur179
Carburateur183
Maintenance Intervals188
Regular Inspection and Adjustments188
Culasse191
De Soupapes191
Filtre a Huile, Pompe192
Mise en Marche Et Rodage192
Regelmässige Wartungs- und Einstellarbeiten194
Motor194
Intervalos de Mantenimiento197
Pre-Operation Inspection and Maintenance200
General Inspection and Maintenance200
Engine200
Chassis200
Routinekontrolle vor Fahrtbeginn202
Revisión Previay Mantenimiento203
Engine204
Coolant Level Inspection204
Coolant Replacement204
Motor205
And Side Covers206
Handling Notes of Coolant208
Radiator Cap Inspection210
Radiator Cap Opening Pressure Inspection210
Cooling System Inspection212
Clutch Adjustment214
Throttle Cable Adjustment214
Throttle Lubrication216
Hot Starter Lever Adjustment216
Air Filter Cleaning218
Engine Oil Level Inspection222
Engine Oil Replacement226
Cambio de Aceite del Motor227
Engine Oil Replacement228
Idle Speed Adjustment230
Tion230
Valve Clearance Adjustment232
Intake240
Exhaust240
Valve Clearance Adjustment240
Spark Arrester Cleaning244
Arriere245
Chassis246
Brake System Air Bleeding246
Chasis247
Front Brake Adjustment248
Brake Lever Position Adjustment Steps248
Rear Brake Adjustment250
Front Brake Pad Inspection and Replacement250
Fourche253
Rear Brake Pad Inspection and Replacement254
Rear Brake Pad Insulator Inspection258
Brake Fluid Level Inspection258
Sprockets Inspection260
Drive Chain Inspection260
Drive Chain Slack Adjustment264
Drive Chain Stopper Inspection266
Front Fork Inspection266
Front Fork Oil Seal and Dust Seal Cleaning266
Front Fork Internal Pressure Relieving268
Front Fork Rebound Damping Force Adjustment268
Front Fork Compression Damping Force Adjustment270
Rear Shock Absorber Inspection272
Rear Shock Absorber Spring Preload Adjustment274
Rear Shock Absorber Rebound Damping Force Adjustment276
Rear Shock Absorber Low Compression Damping Force Adjustment278
Rear Shock Absorber High Compression Damping Force Adjustment280
Tire Pressure Check282
Spokes Inspection and Tightening282
Wheel Inspection282
Steering Head Inspection and Adjustment284
Lubrication290
Lenker291
Spark Plug Inspection292
Electrical292
Sistema Eléctrico293
Ignition Timing Check294
Battery Inspection and Charging296
Charging Method Using a Variable Voltage Charger304
Fuse Inspection312
Replacing the Headlight Bulbs314
Adjusting the Headlight Beams316
Seat, Fuel Tank and Side Covers318
Removal Points320
Side Cover320
Exhaust Pipe and Silencer322
Tubo de Escape y Silenciador323
Inspection324
Tubo de Escape325
Y Silenciador325
Radiator326
Radiador327
Handling Note328
Carburetor332
Carburador333
Carburetor Disassembly334
Needle Valve340
Throttle Valve340
Jet Needle340
Float Height340
Float342
Starter Plunger342
Accelerator Pump344
Air Cut Valve344
Accelerator Pump Timing Adjustment352
Carburetor Installation354
Air Induction System358
Sistema de Inducción de Aire361
Camshafts362
Cylinder Head Cover362
Ejes de Levas367
Camshaft Sprocket370
Decompression System372
Timing Chain Tensioner372
Cylinder Head380
Culata381
Valves and Valve Springs388
Soupapes Et Ressorts de Soupapes389
Ventile und Ventilfedern389
Valve Lifter and Valve Cotter390
Válvulas y Muelles de Válvulas391
Valve Inspection392
Valve Spring400
Valve Lifter400
Cylinder and Piston406
Zylinder und Kolben407
Piston408
Piston Ring408
Cilindro y Pistón409
Piston Pin414
Clutch418
Embrague419
Clutch Boss422
Clutch Housing and Boss422
Primary Driven Gear422
Clutch Spring422
Friction Plate424
Clutch Plate424
Push Lever424
Oil Filter, Water Pump and Crankcase Cover (Right)432
Filtro de Aceite433
Impeller Shaft436
Oil Seal436
Crankcase Cover (Right)440
Y Tapa del Cárter441
Kick Crank442
Water Pump Housing442
Oil Filter444
Balancer446
Compensador447
Balancer Drive Gear and Balancer Driven Gear448
Primary Drive Gear, Balancer Drive Gear and Balancer Driven Gear448
Oil Pump452
Bomba de Aceite453
Kick Axle and Shift Shaft460
Arbre de Kick Et Axe de Selecteur461
Kickhebelwelle und Schaltwelle461
Eje del Pedal de Arranque y Eje del Cambio461
Kick Axle Assembly464
Shift Guide and Shift Lever Assembly464
Kick Axle and Ratchet Wheel464
Kick Gear, Kick Idle Gear and Ratchet Wheel464
Eje del Pedal de Arranque465
Shift Shaft466
Stopper Lever466
Segment466
Y Eje del Cambio467
Kick Idle Gear472
Ac Magneto and Starter Clutch474
Magneto Ca y Embrague del Motor de Arranque475
Lichtmaschine und Starterkupplung475
Rotor478
AC Magneto478
Woodruff Key478
Starter Clutch480
Torque Limiter480
Engine Removal488
Desmontaje del Motor489
Motor Demontieren489
Drive Sprocket494
Engine Installation496
Brake Pedal496
Crankcase and Crankshaft500
Cárter y Cigüeñal501
Carter Moteur Et Vilebrequin501
Crankcase Bearing504
Caja de Cambios, Leva505
De Cambio y Horquilla505
Crankcase506
Crankshaft508
Crankshaft Bearing508
Timing Chain and Timing Chain Guide508
Oil Strainer510
Oil Delivery Pipe 2510
Transmission, Shift Cam and Shift Fork518
De Cambio519
Shift Fork, Shaft Cam and Transmission520
Gears520
Shift Fork, Shift Cam and Segment522
Transmission522
Front Wheel and Rear Wheel528
Chassis528
Chasis529
Rueda Delantera529
Roue Avant Et Roue Arriere529
Rear Wheel530
Y Rueda Trasera531
Wheel Bearing (if Necessary)532
Wheel532
Wheel Axle534
Brake Disc534
Front Wheel536
Front Brake and Rear Brake546
Freno Delantero547
Frein Avant Et Frein Arriere547
Y Freno Trasero549
Caliper Disassembly550
Master Cylinder Disassembly552
Brake Fluid554
Caliper Piston554
Piston Seal Kit556
Master Cylinder556
Caliper558
Brake Hose558
Front Caliper560
Rear Caliper562
Master Cylinder Kit564
Front Master Cylinder566
Rear Master Cylinder568
Front Brake Hose570
Front Fork578
Horquilla Delantera579
Cap Bolt582
Inner Tube584
Damper Rod584
Base Valve586
Fork Spring586
Outer Tube586
Front Fork Assembly588
Handlebar604
Manillar605
Steering618
Dirección619
Ring Nut622
Bearing (Lower)622
Bearing Race622
Steering Shaft622
Bearing and Bearing Race624
Under Bracket624
Swingarm632
Basculante633
Frein Avant Et Frein Arriere633
Swingarm Disassembly634
Cap636
Relay Arm636
Connecting Rod638
Bearing and Oil Seal638
Rear Shock Absorber648
Amortiguador Trasero649
Et Caches Lateraux649
Tube D'echappement Et Silencieux649
Amortisseur Arriere651
Notes on Disposal654
Electrical Components and Wiring Diagram666
Partie Electrique667
Composants Electriques667
Et Schema de Cablage667
Map-Controlled CDI Unit668
Function of Component668
Principal of 3-Dimensional Control668
Ignition System668
Boitier CDI Commande669
D'admission669
Unidad CDI Controlada por Mapa671
Ignition System672
Systeme D'allumage673
Sistema de Encendido675
Spark Gap Test676
Couplers, Leads and Ignition Coil Connection Inspection676
“Engine Stop” Button Inspection676
Main Switch Inspection678
Ignition Coil Inspection678
Ac Magneto Inspection680
Neutral Switch Inspection680
CDI Unit Inspection680
Electric Starting System682
Starting Circuit Cut-Off System Operation682
Demarrage683
Demarrage Electrique683
Couplers and Leads Connection Inspection688
Starter Motor Operation688
Starting Circuit Cut-Off Relay Inspection688
Starter Relay Inspection690
Clutch Switch Inspection690
Diode Inspection692
Start Switch Inspection692
Starter Motor694
Inspection and Repair698
Charging System704
Systeme de Charge705
Sistema de Carga707
Charging Voltage Inspection708
Tps (Throttle Position Sensor) System710
Systeme Tps711
Drosselklappensensor712
Tps Replacement and Adjustment716
Vergaser717
Tps Input Voltage Inspection720
Lighting System722
Beleuchtungsanlage724
Signaling System728
Systeme de Signalisation729
Signalanlage730
Sistema de Señalización731
Kabelanschlüsse Kontrollieren733
Multifunktionsanzeige733
Tuning738
Carburetor Setting738
Abstimmung739
Motor739
Reglaje739
Atmospheric Conditions and Carburetor Settings740
Effects of the Setting Parts on the Throttle Valve Opening742
Main System742
Main Jet Adjustment744
Effects of Changing the Main Jet (Reference)744
Pilot Jet Adjustment744
Effects of Adjusting the Pilot Jet (Reference)744
Jet Needle Groove Position Adjustment746
Effects of Changing the Jet Needle Groove Position (Reference)746
Jet Needle Adjustment746
Effects of Changing the Jet Needle748
Leak Jet Adjustment748
Relationship with Throttle Opening750
Carburetor Setting Parts750
Examples of Carburetor Setting Depending on Symptom752
Kraftstoff754
Combustible755
Selection of the Secondary Reduction Ratio756
Chasis757
Fahrwerk757
Drive and Driven Sprockets Setting Parts758
Tire Pressure758
Front Fork Setting760
Change in Level and Characteristics of Fork Oil760
Teleskopgabel761
Spring Preload Adjustment762
Setting of Spring after Replacement764
Front Fork Setting Parts766
Rear Suspension Setting768
Choosing Set Length768
Federbein773
Rear Shock Absorber Setting Parts774
Suspension Setting776

Brand	Yamaha
Model	WR450F(V)
Category	Motorcycle
Language	English

Yamaha WR450F(V) - User Manual

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Yamaha WR450F(V) Specifications

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