Yamaha WR450F(Y) 2009 Manuals

Yamaha WR450F(Y) 2009 Manuals

Manuals and User Guides for Yamaha WR450F(Y) 2009. We have 1 Yamaha WR450F(Y) 2009 manual available for free PDF download: Owner's Service Manual

Yamaha WR450F(Y) 2009 Owner's Service Manual

Yamaha WR450F(Y) 2009 Owner's Service Manual (227 pages)

Brand: Yamaha | Category: Motorcycle | Size: 14.95 MB

Table of Contents

Introduction
6
Manual Information
6
Safety Information
6
Manual Format
7
Weights of Machines
7
How to Read Descriptions
8
Illustrated Symbols
8
Table of Contents
9
General Information
10
Chapter 1

11
- Description
  11
  - General Information
    11
  - Important Information
    12
  - Included Parts
    12
  - Machine Identification
    12
  - Checking of Connection
    13
- Special Tools
  14
- Control Functions
  18
  - Basic Mode
    19
  - Multi-Function Display
    19
  - Operation Buttons
    19
  - Screen Display
    19
  - Changeover to Basic Mode/Race Mode
    20
  - Changing Odometer and Tripmeter
    20
  - Putting Measurement on Standby
    20
  - Race Mode
    20
  - Correcting Tripmeter a
    21
  - Resetting Measurement Data
    21
  - Function Diagram
    22
  - Fuel
    24
  - Handling Note
    24
  - Starting a Cold Engine
    24
  - Starting and Break-In
    24
  - Break-In Procedures
    25
  - The Engine Fails to Start
    25
  - Torque-Check Points
    26
  - Cleaning and Storage
    27
  - General Specifications
    28
- Chassis
  29
- Maintenance Specifications
  30
Chapter 2 Specifications

32
- Engine
  35
Chapter 6 Chassis

36
Chapter 4

63
Chapter 5

99
- Radiator
  99
  - Removing the Radiator
    99
  - Checking the Radiator
    101
  - Installing the Radiator
    101
- Carburetor
  102
  - Removing the Carburetor
    102
  - Disassembling the Carburetor
    104
  - Checking the Carburetor
    106
  - Checking the Needle Valve
    106
  - Checking the Throttle Valve
    106
  - Removing the Pilot Screw
    106
  - Checking the Accelerator Pump
    107
  - Checking the Air Cut Valve
    107
  - Checking the Float
    107
  - Checking the Starter Plunger
    107
  - Adjusting the Accelerator Pump Timing
    109
  - Installing the Carburetor
    109
  - Air Induction System
    111
  - Removing the Air Induction System
    111
  - Checking the Air Induction System
    112
- Camshafts
  113
  - Removing the Cylinder Head Cover
    113
  - Removing the Camshafts
    114
  - Checking the Camshaft
    115
  - Checking the Camshaft Sprocket
    116
  - Checking the Decompression System
    116
  - Checking the Timing Chain Tensioner
    116
  - Installing the Camshaft
    117
- Cylinder Head
  118
  - Removing the Cylinder Head
    118
  - Checking the Cylinder Head
    119
  - Installing the Cylinder Head
    119
  - Warpage Measurement and Resurfacing
    119
  - Removing the Valves and Valve Springs
    121
  - Valves and Valve Springs
    121
  - Checking the Valve
    122
  - Removing the Valve Lifter and Valve Cotter
    122
  - Checking the Valve Lifters
    124
  - Checking the Valve Springs
    124
  - Installing the Valves
    124
  - Cylinder and Piston
    125
  - Removing the Cylinder and Piston
    125
  - Checking the Cylinder and Piston
    126
  - Checking the Piston Ring
    126
  - Removing the Piston and Piston Ring
    126
  - Checking the Piston Pin
    127
  - Installing the Cylinder
    127
  - Installing the Piston Ring and Piston
    127
- Clutch
  128
  - Removing the Clutch
    128
  - Checking the Clutch Housing and Boss
    130
  - Checking the Clutch Springs
    130
  - Checking the Primary Driven Gear
    130
  - Removing the Clutch Boss
    130
  - Oil Filter Element and Water Pump
    132
  - Removing the Oil Filter Element and Water Pump
    132
  - Checking the Bearing
    134
  - Checking the Impeller Shaft
    134
  - Removing the Impeller Shaft
    134
  - Removing the Oil Seal
    134
  - Installing the Kickstarter Crank
    135
  - Installing the Water Filter Element
    135
  - Installing the Water Pump Housing
    135
- Balancer
  136
Chapter 3

136
- Removing the Balancer
  136
- Checking the Balancer
  137
- Checking the Balancer Shaft Driven Gear
  137
- Checking the Primary Drive Gear, Balancer Shaft Drive Gear
  137
- Installing the Balancer
  137
- Oil Pump
  138
  - Removing the Oil Pump
    138
  - Checking the Oil Pump
    140
  - Installing the Oil Pump
    140
  - Kick Shaft and Shift Shaft
    141
  - Removing the Kick Shaft and Shift Shaft
    141
  - Checking the Kick Shaft and Ratchet Wheel
    143
  - Removing the Kick Shaft Assembly
    143
  - Removing the Segment
    143
  - Removing the Shift Guide and Shift Lever Assembly
    143
  - Installing the Kick Idle
    144
  - Installing the Kick Shaft Assembly
    144
  - Installing the Shift Guide and Shift Lever Assembly
    144
  - Installing the Shift Shaft
    144
  - AC Magneto and Starter Clutch
    146
  - Removing the AC Magneto and Starter Clutch
    146
  - Checking the AC Magneto
    148
  - Checking the Woodruff Key
    148
  - Removing the Rotor
    148
  - Removing the Starter Clutch
    148
- Engine Removal
  151
  - Installing the Brake Pedal
    153
  - Installing the Engine
    153
  - Removing the Drive Sprocket
    153
  - Removing the Engine
    153
  - Installing the Neutral Switch
    154
  - Crankcase and Crankshaft
    155
  - Removing the Crankshaft
    155
  - Removing the Crankcase Bearing
    157
  - Checking the Crankcase
    158
  - Checking the Timing Chain and Timing Chain Guide
    158
  - Disassembling the Crankcase
    158
  - Removing the Balancer Shaft
    158
  - Checking the Crankshaft
    159
  - Checking the Oil Strainer
    159
  - Installing the Crankcase Bearing
    159
  - Installing the Crankshaft
    159
  - Removing the Transmission, Shift Cam and Shift Fork
    161
  - Transmission, Shift Cam and Shift Fork
    161
  - Checking the Gears
    162
  - Checking the Shift Fork, Shift Cam and Segment
    162
  - Installing the Transmission
    162
  - Removing the Transmission
    162
  - Front Wheel and Rear Wheel
    164
  - Removing the Front Wheel
    164
  - Removing the Rear Wheel
    165
  - Checking the Brake Disc
    166
  - Checking the Wheel
    166
  - Checking the Wheel Axle
    166
  - Removing the Wheel Bearing
    166
  - Installing the Rear Wheel
    167
  - Front Brake and Rear Brake
    169
  - Removing the Front Brake
    169
  - Removing the Rear Brake
    170
  - Disassembling the Brake Caliper
    171
  - Disassembling the Brake Master Cylinder
    172
  - Checking the Brake Master Cylinder
    173
  - Draining the Brake Fluid
    173
  - Removing the Brake Caliper Piston
    173
  - Removing the Brake Caliper Piston Seal Kit
    173
  - Checking the Brake Caliper
    174
  - Checking the Brake Hose
    174
  - Installing the Brake Caliper Piston
    174
  - Installing the Front Brake Caliper
    174
  - Installing the Brake Master Cylinder Kit
    175
  - Installing the Rear Brake Caliper
    175
  - Installing the Front Brake Hose
    176
  - Installing the Front Brake Master Cylinder
    176
  - Installing the Rear Brake Master Cylinder
    176
  - Filling the Brake Fluid
    177
  - Installing the Rear Brake Hose
    177
- Front Fork
  179
  - Removing the Front Fork
    179
  - Disassembling the Front Fork
    180
  - Checking the Damper Rod
    181
  - Removing the Damper Rod
    181
  - Removing the Front Fork Cap Bolt
    181
  - Removing the Inner Tube
    181
  - Assembling the Front Fork
    182
  - Checking the Front Fork Cap Bolt
    182
  - Checking the Outer Tube
    182
  - Installing the Front Fork
    185
- Handlebar
  186
  - Removing the Handlebar
    186
  - Checking the Handlebar
    187
  - Installing the Handlebar
    187
  - Removing the Brake Master Cylinder
    187
  - Removing the Grip
    187
  - Removing the Steering
    190
- Steering
  190
  - Checking the Bearing and Bearing Race
    192
  - Removing the Bearing Race
    192
  - Removing the Lower Bearing
    192
  - Removing the Steering Ring Nut
    192
  - Removing the Swingarm
    194
- Swingarm
  194
  - Disassembling the Swingarm
    195
  - Checking the Swingarm
    196
  - Installing the Bearing and Oil Seal
    196
  - Removing the Bearing
    196
  - Removing the Cap
    196
  - Rear Shock Absorber
    199
  - Removing the Rear Shock Absorber
    199
  - Rear Shock Absorber
    200
  - Checking the Rear Shock Absorber
    201
  - Installing the Bearing
    201
  - Notes on Disposal
    201
  - Installing the Rear Shock Absorber
    202
  - Installing the Spring (Rear Shock Absorber)
    202
  - Elwctrical Components and Wiring Diagram
    205
  - Electrical Components and Wiring Diagram
    206
Chapter 7

207
- Ignition System
  207
  - Inspection Steps
    207
  - Checking the Couplers, Leads and Ignition Coil Connection
    208
  - Checking the Engine Stop Switch
    208
  - Checking the Main Switch
    208
  - Spark Gap Test
    208
  - Checking the Neutral Switch
    209
  - Electric Starting System
    209
  - Starting Circuit Cut-Off System Operation
    209
  - Checking the Clutch Switch
    211
  - Checking the Starter Motor Operation
    211
  - Checking the Starter Relay
    211
  - Checking the Starting Circuit Cut-Off Relay
    211
  - Checking the Start Switch
    212
  - Removing the Starter Motor
    213
  - Disassemling the Starter Motor
    214
  - Assembling the Starter Motor
    215
  - Chexking and Repairing the Starter Motor
    215
- Charging System
  217
- Lighting System
  222
  - Checking the Rectifier/Regulator
    223
  - Checking the Taillight
    223
- Signaling System
  224

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