Yamaha WR450FB 2012 Manuals

Manuals and User Guides for Yamaha WR450FB 2012. We have 2 Yamaha WR450FB 2012 manuals available for free PDF download: Owner's Service Manual

Yamaha WR450FB 2012 Owner's Service Manual (392 pages)

Brand: Yamaha | Category: Motorcycle | Size: 25.99 MB

Table of Contents
9
General Information
11
Location of Important Labels
13
Description
15
Consumer Information
16
Vehicle Identification Number
16
Engine Serial Number
16
Model Label
16
Vehicle Emission Control Information Label
16
Features
17
Outline of the Fi System
17
Fi System
18
Included Parts
19
Valve Joint
19
Spark Plug Wrench
19
Nipple Wrench
19
Handlebar Protector
19
Hook (Fuel Tank)
19
Fuel Hose Joint Cover
19
Coupler for Connecting Optional Part
20
Important Information
20
Preparation for Removal and Disassembly
20
Replacement Parts
20
Gaskets, Oil Seals and O-Rings
21
Lock Washers/Plates and Cotter Pins
21
Bearings and Oil Seals
21
Circlips
21
Basic Service Information
23
Electrical System
23
Special Tools
29
Control Functions
32
Main Switch
32
Indicator Lights and Warning Lights
32
Engine Stop Switch
32
Start Switch
33
Clutch Lever
33
Shift Pedal
33
Kickstarter Crank
33
Throttle Grip
33
Front Brake Lever
33
Rear Brake Pedal
34
Sidestand
34
Starter Knob/Idle Adjusting Screw
34
Multi-Function Display
34
Description
34
Basic Mode
35
Changeover to Basic Mode/Race Mode
36
Race Mode
37
Function Diafram
41
Starting and Break-In
42
Fuel
42
Handling Note
43
Air Filter Maintenance
43
Starting a Cold Engine
43
Starting a Warm Engine
43
Break-In Procedures
44
Torque-Check Points
45
Motorcycle Care and Storage
46
Care
46
Storage
47
Specifications
49
General Specifications
50
Engine Specifications
51
Chassis Specifications
57
Electrical Specifications
60
Tightening Torques
62
General Tightening Torque Specifications
62
Engine Tightening Torques
63
Chassis Tightening Torques
66
Lubrication Points and Lubricant Types
70
Engine
70
Chassis
72
Lubrication System Chart and Diagrams
74
Lubrication Diagrams
74
Cable Routing
78
Periodic Checks and Adjustments
91
Periodic Maintenance
92
Introduction
92
Periodic Maintenance Chart for the Emission Control System
92
General Maintenance and Lubrication Chart
92
Maintenance Intervals for Competition Use
94
Checking the Fuel Line
97
Checking the Spark Plug
97
Adjusting the Valve Clearance
98
Cleaning the Air Filter Element
100
Checking the Breather Hoses
101
Adjusting the Engine Idling Speed
102
Checking the Exhaust System
103
Checking the Engine Oil Level
103
Changing the Engine Oil
104
Adjusting the Clutch Lever Free Play
106
Checking the Coolant Level
106
Checking the Cooling System
107
Changing the Coolant
107
Cleaning the Spark Arrester
108
Checking the Brake Fluid Level
108
Adjusting the Front Disc Brake
109
Checking the Front Brake Pads
109
Adjusting the Rear Disc Brake
110
Checking the Rear Brake Pads
110
Checking the Rear Brake Pad Insulator
110
Bleeding the Hydraulic Brake System
111
Checking the Front Brake Hose
112
Checking the Rear Brake Hose
112
Checking the Wheels
112
Checking and Tightening the Spokes
112
Checking the Tires
113
Checking the Wheel Bearings
114
Checking the Swingarm Operation
114
Adjusting the Drive Chain Slack
114
Lubricating the Drive Chain
115
Checking and Adjusting the Steering Head
115
Lubricating the Levers
116
Lubricating the Pedal
116
Lubricating the Sidestand
116
Checking the Front Fork
116
Adjusting the Front Fork Legs
116
Air Bleeding from Front Fork
117
Checking the Rear Suspension
118
Adjusting the Rear Shock Absorber Assembly
118
Checking the Connecting Arm and Relay Arm
120
Checking and Lubricating the Cables
120
Adjusting the Throttle Grip Free Play
120
Checking the Chassis Fasteners
121
Checking and Charging the Battery
121
Tuning
123
Chassis
124
Selection of the Secondary Reduction Ratio (Sprocket)
124
Drive and Rear Wheel Sprockets Setting Parts
124
Tire Pressure
124
Front Fork Setting
125
Change in Amount and Characteristics of Fork Oil
125
Setting of Spring after Replacement
125
Front Fork Setting Parts
126
Rear Suspension Setting
126
Choosing Set Length
126
Setting of Spring after Replacement
127
Rear Shock Absorber Setting Parts
128
Suspension Setting (Front Fork)
129
Suspension Setting (Rear Shock Absorber)
131
General Chassis
138
Removing the Side Cover
138
Front Wheel
140
Removing the Front Wheel
140
Checking the Front Wheel
140
Disassembling the Front Wheel
141
Assembling the Front Wheel
141
Installing the Front Wheel (Disc)
142
Rear Wheel
145
Removing the Rear Wheel
145
Checking the Rear Wheel
145
Disassembling the Rear Wheel
145
Checking and Replacing the Rear Wheel Sprocket
145
Assembling the Rear Wheel
146
Installing the Rear Wheel (Disc)
147
Front Brake
151
Introduction
154
Checking the Front Brake Disc
154
Replacing the Front Brake Pads
155
Removing the Front Brake Caliper
156
Disassembling the Front Brake Caliper
156
Checking the Front Brake Caliper
156
Assembling the Front Brake Caliper
157
Installing the Front Brake Caliper
157
Removing the Front Brake Master Cylinder
158
Checking the Front Brake Master Cylinder
158
Assembling the Front Brake Master Cylinder
158
Installing the Front Brake Master Cylinder
159
Rear Brake
163
Introduction
166
Checking the Rear Brake Disc
166
Replacing the Rear Brake Pads
166
Removing the Rear Brake Caliper
167
Disassembling the Rear Brake Caliper
167
Checking the Rear Brake Caliper
168
Assembling the Rear Brake Caliper
168
Installing the Rear Brake Caliper
168
Removing the Rear Brake Master Cylinder
169
Checking the Rear Brake Master Cylinder
170
Assembling the Rear Brake Master Cylinder
170
Installing the Rear Brake Master Cylinder
170
Handlebar
173
Removing the Handlebar
173
Checking the Handlebar
173
Installing the Handlebar
173
Front Fork
181
Removing the Front Fork Legs
181
Disassembling the Front Fork Legs
181
Checking the Front Fork Legs
182
Assembling the Front Fork Legs
183
Installing the Front Fork Legs
189
Steering Head
193
Removing the Lower Bracket
193
Checking the Steering Head
193
Installing the Steering Head
193
Rear Shock Absorber Assembly
198
Handling the Rear Shock Absorber
198
Disposing of a Rear Shock Absorber
198
Removing the Rear Shock Absorber Assembly
198
Checking the Rear Shock Absorber Assembly
198
Checking the Connecting Arm and Relay Arm
199
Installing the Relay Arm
199
Installing the Rear Shock Absorber Assembly
199
Swingarm
201
Removing the Swingarm
203
Checking the Swingarm
203
Installing the Swingarm
204
Chain Drive
205
Removing the Drive Chain
206
Checking the Drive Chain
206
Checking the Drive Sprocket
207
Checking the Rear Wheel Sprocket
207
Installing the Drive Chain
207
Engine
209
Engine Removal
213
Removing the Engine
215
Cleaning the Spark Arrester
215
Installing the Engine
216
Installing the Exhaust Pipe and Muffler
216
Installing the Shift Pedal
217
Camshaft
218
Removing the Camshaft
219
Checking the Camshaft
220
Checking the Timing Chain and Camshaft Sprocket
222
Checking the Timing Chain Tensioners
222
Checking the Decompression System
223
Installing the Camshafts
223
Cylinder Head
225
Removing the Cylinder Head
226
Checking the Timing Chain Guide (Exhaust Side)
226
Checking the Cylinder Head
226
Installing the Cylinder Head
227
Valves and Valve Springs
230
Removing the Valves
230
Checking the Valves and Valve Guides
231
Checking the Valve Seats
232
Checking the Valve Springs
234
Checking the Valve Lifters
235
Installing the Valves
235
Cylinder and Piston
237
Removing the Piston
238
Checking the Cylinder and Piston
238
Checking the Piston Rings
239
Checking the Piston Pin
240
Installing the Piston and Cylinder
240
Electric Starter
242
Checking the Starter Motor
244
Assembling the Starter Motor
245
Clutch
249
Removing the Clutch
250
Checking the Friction Plates
250
Checking the Clutch Plates
250
Checking the Clutch Springs
250
Checking the Clutch Housing
251
Checking the Clutch Boss
251
Checking the Pressure Plate
251
Checking the Clutch Push Rods
251
Checking the Primary Drive Gear
252
Checking the Primary Driven Gear
252
Installing the Clutch
252
Kickstater
256
Removing the Kick Shaft Assembly
256
Checking the Kick Shaft and Ratchet Wheel
256
Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
256
Installing the Kick Shaft Assembly
256
Installing the Kick Idle Gear
257
Shift Shaft
258
Removing the Segment
260
Checking the Shift Shaft
260
Checking the Stopper Lever
260
Installing the Segment
260
Installing the Stopper Lever
260
Installing the Shift Guide and Shift Lever Assembly
261
Installing the Shift Shaft
261
Oil Pump and Balancer Gear
262
Removing the Balancer
265
Checking the Oil Pump
265
Assembling the Oil Pump
266
Installing the Oil Pump and Balancer Gear
266
Generator and Starter Clutch
268
Removing the Generator
270
Checking the Starter Clutch
270
Installing the Starter Clutch
271
Installing the Generator
271
Crankcase
274
Disassembling the Crankcase
276
Checking the Timing Chain, Timing Chain Guide, Oil Strainer
276
Checking the Crankcase
276
Assembling the Crankcase
277
Crankshaft Assembly and Balancer Shaft
278
Removing the Balancer Shaft
279
Removing the Crankshaft Assembly
279
Checking the Crankshaft Assembly
279
Installing the Crankshaft Assembly
280
Cooling System
288
Radiator
288
Handling Note
288
Checking the Radiator
288
Installing the Radiator
288
Water Pump
290
Checking the Water Pump
291
Assembling the Water Pump
291
Fuel System
293
Fuel Tank
294
Removing the Fuel Tank
296
Removing the Fuel Pump
296
Checking the Fuel Pump Body
296
Installing the Fuel Pump
296
Removing the Fuel Sender
297
Checking the Fuel Sender
297
Installing the Fuel Sender
297
Installing the Fuel Tank
298
Checking the Fuel Pressure
298
Throttle Body
299
Removing the Throttle Body
301
Checking the Injector
301
Checking the Throttle Body
301
Checking the Throttle Body Joint
302
Adjusting the Throttle Position Sensor
302
Electrical System
303
Ignition System
306
Circuit Diagram
306
Troubleshooting
308
Electric Starting System
310
Circuit Diagram
310
Starting Circuit Cut-Off System Operation
312
Troubleshooting
314
Charging System
316
Circuit Diagram
316
Troubleshooting
318
Lighting System
320
Circuit Diagram
320
Troubleshooting
322
Signaling System
324
Circuit Diagram
324
Troubleshooting
326
Fuel Injection System
328
Circuit Diagram
328
Yamaha Diagnostic Tool
330
Ecu Self-Diagnostic Function
331
Troubleshooting Method
333
List of Self-Diagnostic and Fail-Safe Actions
334
List of Diagnostic Codes
335
Troubleshooting Details
337
Fuel Pump System
356
Circuit Diagram
356
Trouble Shooting
358
Electrical Components
360
Checking the Switches
364
Checking the Bulbs and Bulb Sockets
368
Replacing the Headlight Bulb
369
Checking the Fuse
369
Checking and Charging the Battery
370
Checking the Relays
373
Checking the Diode
374
Checking the Ignition Spark Gap
375
Checking the Spark Plug Cap
375
Checking the Ignition Coil
375
Checking the Crankshaft Position Sensor
376
Checking the Lean Angle Sensor
376
Checking the Starter Motor Operation
377
Checking the Stator Coil
377
Checking the Rectifier/Regulator
378
Checking the Speed Sensor
378
Checking the Fuel Sender
378
Checking the Coolant Temperature Sensor
379
Checking the Throttle Position Sensor
380
Checking the Throttle Position Sensor Input Voltage
380
Checking the Intake Air Pressure Sensor
381
Checking the Intake Air Temperature Sensor
381
Checking the Fuel Injector
382
Troubleshooting
383
Troubleshooting
384
Starting Failures
384
Incorrect Engine Idling Speed
384
Poor Medium-And-High-Speed Performance
385
Faulty Gear Shifting
385
Shift Pedal Does Not Move
385
Jumps out of Gear
385
Faulty Clutch
385
Overheating
386
Overcooling
386
Poor Braking Performance
386
Faulty Front Fork Legs
386
Unstable Handling
386
Faulty Lighting System
387

Yamaha WR450FB 2012 Owner's Service Manual (387 pages)

Brand: Yamaha | Category: Motorcycle | Size: 49.43 MB

Table of Contents

7
- General Information
  8
- Location of Important Labels
  
  11
- Description
  
  12
- Consumer Information
  
  13
  - Vehicle Identification Number
    13
  - Engine Serial Number
    13
  - Model Label
    13
  - Vehicle Emission Control Information Label
    13
- Features
  
  14
  - OUTLINE of the Fl SYSTEM
    14
  - Fl SYSTEM
    15
- Included Parts
  
  16
  - Valve Joint
    16
  - Spark Plug Wrench
    16
  - Nipple Wrench
    16
  - Handlebar Protector
    16
  - Hook (Fuel Tank)
    16
  - Fuel Hose Joint Cover
    16
- Important Information
  
  17
  - Replacement Parts
    17
  - Gaskets, Oil Seals and 0-Rings
    18
  - Lock Washers/Plates and Cotter Pins
    18
  - Bearings and Oi Lseals
    18
  - Circlips
    18
- Basic Service Information
  
  19
  - Quick Fasteners
    19
  - Electrical System
    20
- Special Tools
  
  24
- Control Functions
  
  29
  - Main Switch
    29
  - Indicator Lights and Warning Lights
    29
  - Engine Stop Switch
    29
  - Start Switch
    30
  - Clutch Lever
    30
  - Shift Pedal
    30
  - Kickstarter Crank
    30
  - Throttle Grip
    30
  - Front Brake Lever
    30
  - Rear Brake Pedal
    31
  - Sidestand
    31
  - Starter Knob/Idle Adjusting Screw
    31
  - MUL Tl-FUNCTION DISPLAY
    31
    
    Description
    31
    
    Basic Mode
    32
    
    Changeover to Basic Mode/Race Mode
    33
    
    Race Mode
    34
    
    Function Diafram
    38
  - Starting and Break-In
    39
    
    Fuel
    39
    
    Handling Note
    40
    
    Air Filter Maintenance
    40
    
    Starting a Cold Engine
    40
    
    Starting a Warm Engine
    40
    
    Break-In Procedures
    41
  - Torque-Check Points
    42
  - Motorcycle Care and Storage
    43
    
    Care
    43
    
    Storage
    44
Specifications

46
- General Specifications
  47
- Engine Specifications
  48
- Chassis Specifications
  56
- Electrical Specifications
  57
- Tightening Torques
  59
- Lubrication Points and Lubricant Types
  67
  - Engine
    67
  - Chassis
    69
- Lubrication System Chart and Diagrams
  71
  - Lubrication Diagrams
    71
- Cable Routing
  75
- Periodic Checks and Adjustments
  88
Tuning

120
- Chassis
  121
- Selection of the Drive and Rear Wheel Sprockets Setting Parts
  121
- Tire Pressure
  121
- Front Fork Setting
  122
- Setting of Spring after Replacement
  122
- Choosing Set Length
  123
- Front Fork Setting Parts
  123
- Rear Suspension Setting
  123
- Rear Shock Absorber Setting Parts
  125
- Suspension Setting
  128
Chassis

130
- General Chassis
  132
  - Removing the Side Cover
    135
- Front Wheel
  136
  - Removing the Front Wheel
    137
  - Checking the Front Wheel
    137
  - Disassembling the Front Wheel
    138
  - Assembling the Front Wheel
    138
  - Installing the Front Wheel (Disc)
    139
- Rear Wheel
  141
  - Removing the Rear Wheel
    142
  - Checking the Rear Wheel
    142
  - Disassembling the Rear Wheel
    142
  - Checking and Replacing the Rear Wheel Sprocket
    142
  - Assembling the Rear Wheel
    143
  - Installing the Rear Wheel (Disc)
    144
- Front Brake
  146
- Rear Brake
  162
  - Introduction
    163
  - Checking the Rear Brake Disc
    163
  - Replacing the Rear Brake Pads
    163
  - Removing the Rear Brake Caliper
    164
  - Checking the Rear Brake Caliper
    165
  - Assemblingtherearbrakecaliper
    165
  - Installing the Rear Brake Caliper
    165
  - Removing the Rear Brake Master Cylinder
    166
  - Checking the Rear Brake Master Cylinder
    167
  - Assembling the Rear Brake Master Cylinder
    167
  - Installing Th Erear Brake Master Cylinder
    167
- Handlebar
  169
  - Removing the Handlebar
    170
  - Checking the Handlebar
    170
  - Installing the Handlebar
    170
  - Removing the Front Fork Legs
    178
  - Disassembling the Front Fork Legs
    178
  - Checking the Front Fork Legs
    179
  - Assemblingthefrontforklegs
    180
  - Installing the Front Fork Legs
    186
- Steering Head
  189
  - Removing the Lower Bracket
    190
  - Checking the Steering Head
    190
  - Installing the Steering Head
    190
- Rear Shock Absorber Assembly
  192
- Swingarm
  198
  - Removing the Swingarm
    200
  - Checking the Swingarm
    200
  - Installing the Swingarm
    201
- Chain Drive
  202
  - Removing the Drive Chain
    203
  - Checking the Drive Chain
    203
  - Checking the Drive Sprocket
    204
  - Checking the Rear Wheel Sprocket
    204
  - Installing the Drive Chain
    204
Engine

206
- Engine Removal
  211
  - Removing the Engine
    212
  - Cleaning the Spark Arrester
    212
  - Installing the Engine
    213
  - Installing the Exhaust Pipe and Muffler
    213
  - Installing the Shift Pedal
    214
  - Camshaft
    215
  - Removing the Camshaft
    216
  - Checking the Camshaft
    217
  - Checking the Decompression System
    220
  - Installing the Camshafts
    220
  - Cylinder Head
    222
  - Removing the Cylinder Head
    223
  - Checking the Timing Chain Guide ( Exhaust Side )
    223
  - Checking the Cylinder Head
    223
  - Installing the Cylinder Head
    224
  - Valves and Valve Springs
    227
  - Removing the Valves
    227
  - Checking the Valves and Valve Guides
    228
  - Checking the Valve Seats
    229
  - Checking the Valve Springs
    231
  - Checking the Valve Lifters
    232
  - Installing the Valves
    232
  - Cylinder and Piston
    234
  - Removing the Piston
    235
  - Checking the Cylinder and Piston
    235
  - Checking the Piston Rings
    236
  - Checking the Piston Pin
    237
  - Installing the Piston and Cylinder
    237
  - Electric Starter
    239
  - Checking the Starter Motor
    241
  - Assembling the Starter Motor
    242
  - Clutch
    244
  - Removing the Clutch
    247
  - Checking the Friction Plates
    247
  - Checking the Clutch Plates
    247
  - Checking the Clutch Springs
    247
    
    Checking the Primary Drive Gear
    249
    
    Checking the Primary Driven Gear
    249
    
    Installing the Clutch
    249
  - Kickstater
    254
    
    Installing the Kick Idle Gear
    254
  - Shift Shaft
    256
    
    Removing the Segment
    257
    
    Checking the Shift Shaft
    257
    
    Checking the Stopper Lever
    257
    
    Installing the Segment
    257
    
    Installing the Stopper Lever
    257
    
    Installing the Shift Guide and Shift Lever Assembly
    258
    
    Installing the Shift Shaft
    258
  - Oil Pump and Balancer Gear
    259
    
    Assembling the Oil Pump
    263
    
    Installing the Oil Pump and Balancer Gear
    263
  - Generator and Starter Clutch
    265
    
    Removing the Generator
    267
    
    Checking the Starter Clutch
    267
    
    Installing the Starter Clutch
    268
    
    Installing the Generator
    268
  - Crankcase
    271
    
    Disassembling the Crankcase
    273
    
    Checking the Timing Chain, Timing Chain Guide, Oil Strainer
    273
    
    Checking the Crankcase
    273
    
    Assembling the Crankcase
    274
    
    Crankshaft Assembly and Balancer Shaft
    275
  - Crankshaft Assembly and Balancer Shaft
    276
    
    Removing the Balancer Shaft
    276
    
    Removing the Crankshaft Assembly
    276
    
    Checking the Crankshaft Assembly
    276
    
    Installing the Crankshaft Assembly
    277
Cooling System

282
- Radiator
  283
  - Handling Note
    285
  - Checking the Radiator
    285
  - Installing the Radiator
    285
- Water Pump
  288
  - Checking the Water Pump
    288
  - Assembling the Water Pump
    288
Fuel System

290
- Fuel Tank
  291
- Installing the Fuel Pump
  293
- Removing the Fuel Pump
  293
- Removing the Fuel Tank
  293
- Checking the Fuel Sender
  294
- Installing the Fuel Sender
  294
- Removing the Fuel Sender
  294
- Checking the Fuel Pressure
  295
- Installing the Fuel Tank
  295
- Throttle Body
  296
- Checking the Injector
  298
- Checking the Throttle Body
  298
- Removing the Throttle Body
  298
- Adjusting the Throttle Position Sensor
  299
- Checking the Throttle Body Joint
  299
Electrical System

300
- Ignition System
  303
  - Circuit Diagram
    303
  - Troubleshooting
    305
- Electric Starting System
  307
  - Circuit Diagram
    307
  - Starting Circuit Cut-Off System Operation
    309
  - Troubleshooting
    311
- Charging System
  313
  - Circuit Diagram
    313
  - Troubleshooting
    315
- Lighting System
  317
  - Circuit Diagram
    317
  - Troubleshooting
    319
- Signaling System
  321
  - Circuit Diagram
    321
  - Troubleshooting
    323
- Fuel Injection System
  325
  - Circuit Diagram
    325
  - Yamaha Diagnostic Tool
    327
  - Ecu Self-Diagnostic Function
    328
  - Troubleshootin Gmethod
    330
  - List of Self-Diagnostic and Fail-Safe Actions
    331
  - List of Diagnostic Codes
    332
  - Troubleshooting Details
    334
- Fuel Pump System
  353
  - Circuit Diagram
    353
  - Trouble Shooting
    355
- Electrical Components
  357
  - Checking the Switches
    361
  - C Hecking the Bulbs and Bulb Sockets
    365
  - Replacing the Headlight Bulb
    366
  - Checking the Fus E
    366
  - Checking and Charging the Battery
    367
  - Checking Th Erelays
    370
  - Checking the Diode
    371
  - Checking Th Eignition Spark Gap
    372
  - Checking the Spark Plug Cap
    372
- Checking the Ignition Coil
  372
- Checking the Crankshaft Position Sensor
  373
- Checking the Lean Angle Sensor
  373
- Checking the Starter Motor Operation
  374
- Checking the Stator Coil
  374
- Checking the Fuel Sender
  375
- Checking the Rectifier/Regulator
  375
- Checking the Speed Sensor
  375
- Checking the Coolant Temperature Sensor
  376
- Checking the Throttle Position Sensor
  377
- Checking the Throttle Position Sensor Inputvoltage
  377
- Checking the Intake Air Pressure Sensor
  378
- Checking the Fuel Injector
  379
- Troubleshooting
  381
  - General Information
    381
  - Starti Ng Failures
    381
  - Incorrect Engine Idling Speed
    381
  - Faulty Clutch
    382
  - Overheating
    383
  - Overcooling
    383
  - Poor Braking Performance
    383
  - Faulty Front Fork Legs
    383
  - Faulty Li Ghti Ng System
    384

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Table of Contents

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Table of Contents

Table of Contents

Location of Important Labels

Description

Consumer Information

Features

Included Parts

Important Information

Basic Service Information

Special Tools

Control Functions

Specifications

Tuning

Chassis

Engine

Cooling System

Fuel System

Electrical System

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