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Yamaha WR450FB 2012 Owner's Service Manual
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Yamaha WR450FB 2012 Owner's Service Manual

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  • Page 7: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST- MENTS TUNING CHASIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLE SHOOTING...

  • Page 206: Engine

    ENGINE ENGINE REMOVAL ..................6-1 REMOVING THE ENGINE ................. 6-4 CLEANING THE SPARK ARRESTER ............6-4 INSTALLING THE ENGINE ..............: ..6-5 INSTALLING THE EXHAUST PIPE AND MUFFLER ......... 6-5 INSTALLING THE SHIFT PEDAL .............. 6-6 CAMSHAFT ...................... 6-7 REMOVING THE CAMSHAFT ..............

  • Page 244: Clutch

    CLUTCH the clutch ,�rg 6-36...
  • Page 245 CLU TCH Remo ving the clutch 10 Nm (1.0 m, kgf, 7.2 ft, lbf) 33 Nm (3.3 m , kgf, 24 ft , lbf) 12 Nm (1.2 m, kgf, 8.7 ft, lbf) 10 Nm (1.0 m. kgf, 7.2 ft· lbf) 10 Nm (1.0 m, kgf, 7.2 ft.
  • Page 246 CLUTCH Removing the clutch 10 Nm (1.0 m. kgf, 7.2 ft· lbf) 33 Nm (3.3 m • kgf, 24 ft - lbf) 12 Nm (1.2 m • kgf, 8. 7 ft • lbf) 10 Nm (1.0 m • kgf, 7.2 ft• lbf) Order Job/Parts to remove Remarks...

  • Page 247: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Remove: • Clutch boss nut "1" • Conical washer "2" • Clutch boss "3" TIP ______________ While holding the clutch boss with the universal clutch holder "4", loosen the clutch boss nut. Universal clutch holder EAS25110 CHECKING THE CLUTCH PLATES...

  • Page 249: Checking The Primary Drive Gear

    CLUTCH CHECKING THE PRIMARY DRIVE GEAR 1. Check: • Primary drive gear Damage/wear -+ Replace the primary drive and primary driven gears as a set. Excessive noise during operation -+ Re­ place the primary drive and primary driven gears as a set. 2.
  • Page 250 CLUTCH 6. Install: 4. Install: • Push rod 2 "1" • Friction plate "1" • Ball "2" • Clutch plate 1 [t=2.0 mm (0.079 in)] "2" • Push rod 1 "3" • Clutch plate 2 [t=1.6 mm (0.063 in)] "3" TIP _____________ _ TIP _____________ _ •...

  • Page 254: Kickstater

    KICKSTATER 5. Hook: • Torsion spring "1" TIP ____________ _ Turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase. 3. Install: • Spring guide "1" TIP _____________ _ Slide the spring guide into the kick shaft, make sure the groove "a"...

  • Page 256: Shift Shaft

    SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m. kgf, 7.2 ft. lbf) 30 Nm (3.0 m · kgf, 22 ft · lbf) Order Job/Parts to remove Remarks Q'ty Washer Stopper lever spring Segment For installation, reverse the removal proce­ dure.

  • Page 257: Removing The Segment

    SHIFT SHAFT EAS10X3180 REMOVING THE SEGMENT 1. Remove: • Bolt (segment) "1" • Segment "2" TIP _____________ _ Turn the segment counterclockwise until it stops and loosen the bolt. ECA1DX1021 If the segment gets an impact, it may be EAS1DX3181 damaged.

  • Page 258: Installing The Shift Guide And Shift Lever Assembly

    SHIFT SHAFT ----- 4. Install: • Shift guide bolt "1" EAS1DX3183 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY Shift guide bolt 1. Install: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Spring "1" • Pawl pin "2" • Pawl "3" To shift lever "4".

  • Page 259: Oil Pump And Balancer Gear

    OIL PUMP AND BALANCER GEAR EAS1DX3184 OIL PUMP AND BALANCER GEAR Removing the oil pump and balancer 45 Nm (4.5 m • kgf, 33 ft · lbf) 10 Nm (1.0 m. kgf, 7.2 ft. lbf) 110 Nm (11.0 m • kgf, 80 ft• lbf) 50 Nm (5.0 m •...
  • Page 260 OIL PUMP AND BALANCER GEAR Removing the oil pump and balancer 45 Nm (4.5 m • kgf, 33 ft , lbf) 10 Nm (1.0 m, kgf, 7.2 ft• lbf) lbf) 110 Nm (11.0 m • kgf, 80 ft 50 Nm (5.0 m • kgf, 36 ft , lbf) Order Job/Parts to remove Remarks...
  • Page 261 OIL PUMP AND BALANCER GEAR Disassembling the oil pump 2 Nm (0.2 m • kgf, 1.4 ft· lbf) Order Job/Parts to remove Remarks Q'ty Oil pump cover Outer rotor 1 Inner rotor 1 Dowel pin Washer Oil pump drive shaft Rotor housing For assembly, reverse the disassembly pro- cedure.

  • Page 263: Assembling The Oil Pump

    OIL PUMP AND BALANCER GEAR EAS1DX3187 ASSEM BLING THE OIL PUMP 1. Install: • Oil pump drive shaft "1" • Washer"2" •• Dowel pin "3" • Inner rotor 1 "4" TIP _____ _____ _ _ _ _ • Apply the engine oil on the oil pump drive shaft and inner rotor 1.
  • Page 264 OIL PUMP AND BALANCER GEAR • Primary drive gear "3" • Conical washer "4"1m1J 5 " • Primary drive gear nut Primary drive gear nut 110 Nm (11.0 m·kgf, 80 fNbf) • Straight key "6" • Balancer "7" • Lock washer "8"1m1J •...

  • Page 265: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS1DX3189 GENERATOR STARTER CLUTCH Removing the generator /jl:. - lbf)I 12 Nm (1.2 m, leg!, 8.7 ft, · · 7 Nm (0.7 m • kgf, 5.1 ft •lbf) 10 Nm (1.0 m. kgf, 7.2 ft lbf) 10 Nm (1.0 m.
  • Page 266 GENERATOR AND STARTER CLUTCH Removing the generator � 12 Nm (1.2 m • kgf, 8.7 ft lbf) 7 Nm (0.7 m, kgf, 5.1 ft ,lbf) 10 Nm (1.0 m. kgf, 7.2 ft lbf) 10 Nm (1.0 m. kgf, 7.2ft,lbf) 10 Nm (1.0 m. kgf, 7.2ft,lbf) 1: s l Y'·---(@ 6 5 Nm (6.

  • Page 267: Removing The Generator

    GENERATOR AND STARTER CLUTCH EA$1DX3190 2. Check: REMOVING THE GENERATOR • Starter clutch idle gear 1. Remov e : • Starter clutch gear • Generator rotor nut "1" Burrs/chips/roughness/wear� Replace the • Washer defective part (s). 3. Check: • Starter clutch gear Damage/pitting/wear �...

  • Page 268: Installing The Starter Clutch

    • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Starter clutch bolt 16 Nm (1.6 m·kgf, 12 ft-lbf) YAMAHA Bond No. 1215 (Three­ LOCTITE® Bond No. 1215®) 90890-85505 EAS1DX3193 INSTALLING THE GENERATOR 1.
  • Page 269 GENERATOR AND STARTER CLUTCH 2. Install: • Washer • Generator rotor nut "1" Generator rotor nut 65 Nm (6.5 m·kgf, 47 fMbf) TIP _____________ _._ Tighten the generator rotor nut to 65 Nm (6.5 m·kgf, 47 ft-lbf), loosen and retighten the gener­ ator rotor nut to 65 Nm (6.5 m·kgf, 47 ft·lbf).
  • Page 270 CRANKCASE CRANKCASE EAS25540 Separating the crankcase 12 Nm (1.2 m. kgf, 8.7 ft· lbf) 10 Nm (1.0 m • kgf, 7.2 ft· lbf) 10 Nm (1.0 m, kgf, 7.2 ft• lbf) Job/Parts to remove Remarks Order Q'ty Engine Refer to "ENGINE REMOVAL" on page 6-1. Refer to "CYLINDER AND PISTON"...

  • Page 271: Crankcase

    CRANKCASE Separating the crankcase 12 Nm (1.2 m • kgf, 8.7 ft• lbf) 10 Nm (1.0 m • kgf, 7.2 ft• lbf) 10 Nm (1.0 m. kgf, 7.2 ft• lbf) Order Job/Parts to remove Remarks Q'ty For installation, reverse the removal proce­ dure.
  • Page 272 CRANKCASE 6-64...

  • Page 273: Disassembling The Crankcase

    CRANKCASE EAS25570 DISASSEM BLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Remove the crankcase bolts, hose guide and clutch cable holder. ··�·············��·��··�········ c. Remove the dowel pins and 0-ring. 2. Remove: • Balancer shaft "1" TIP ______________ _ Remove the balancer shaft with its flat side "a"...

  • Page 274: Assembling The Crankcase

    (2) stages, with 1/4 turn each. the screw head. 2. Thoroughly clean all the gasket mating sur­ faces and crankcase mating surfaces. 3. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No.1215 (Three � ,?'- Bond No.1215®) 90890-85505 3. M6 x80mm 4. M6x60mm 5.

  • Page 275: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBL V AND BALANCER SHAFT EAS25970 CRANKS HAFT ASSEMB LY AND BALANC ER SHAFT Removing the crankshaft assembly and balancer shaft Order Job/Parts to remove Remarks Q'ty Separate. Crankcase Refer to"CRANKCASE" on page 6-62. Balancer shaft Crankshaft assembly For installation, reverse the removal proce­ dure.

  • Page 276: Crankshaft Assembly And Balancer Shaft

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS26060 EAS1DX3195 REMOVING THE BALANCER SHAFT CHECKING THE CRANKSHAFT ASSEMBLY 1. Measure: 1. Remove: • Crankshaft runout • Balancer shaft "1" Out of specification -, Replace the crank­ TIP _____________ _ shaft, bearing or both. Remove the balancer shaft with its flat side "a"...

  • Page 277: Installing The Crankshaft Assembly

    CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ECA13970 _j _______ _ To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. TIP _____________ _ Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other.
  • Page 278 TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks .._ Q ' t y Order Job/Parts to remove Remarks Separate. Crankcase Refer to"CRANKCASE" on page 6-62. Main axle assembly Drive axle assembly Shift drum Shift fork-R Shift fork-C Shift fork-L Collar For installation, reverse the removal proce-...
  • Page 279 TRANSMISSION EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • Shift fork cam follower "1" • Shift fork pawl "2" Bends/damage/scoring/wear� Replace the shift fork. EAS1DX3196 CHECKING THE TRANSMISSION 1. Measure: •...
  • Page 280 TRANSMISSION • Transmission gear: dogs TIP _____________ _ Cracks/damage/rounded edges -+ Replace • Apply the molybdenum disulfide oil on the in­ the defective gear (s). ner and end surface of the idler gear and on 4. Check: the inner surface of the sliding gear, then in­ •...
  • Page 281 TRANSMISSION 4. Install: • Collar "1" TIP _____________ _ • Apply the lithium soap base grease on the oil seal lip. • When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip. 6. Install: •...

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