drain bolt YAMAHA WR 450F 2003 User Guide

4 - 61
ENG

OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
2. Install:

Water pump housing
1


Bolt (water pump housing)
2


Plain washer
3


Coolant drain bolt
4

T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

3. Install:

O-ring

Coolant pipe
1


Bolt (coolant pipe)
2

T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

Oil filter
1. Install:

Oil filter
1


O-ring
2


Oil filter cover
3


Bolt (oil filter cover)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4 - 76
ENG

AC MAGNETO AND STARTER CLUTCH
AC MAGNETO AND STARTER CLUTCH
Extent of removal:
1
Starter clutch/wheel gear removal
2
Rotor removal
3
Pickup coil/stator removal
Extent of removal Order Part name Q’ty Remarks
AC MAGNETO AND STATOR
REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Bolt [radiator (left)]
Disconnect the AC magneto lead.Refer to “RADIATOR” section.
1 Shift pedal 1
2 Engine guard (left) 1
3 Cover (idle gear 1) 1
4 Idle gear 1 1
5 Bearing 1
6 Shaft 1
7 Crankcase cover (left) 1
8 Gasket 1
31

5 - 11
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000
FRONT BRAKE
Extent of removal:1 Brake hose removal2 Caliper removal
3 Master cylinder removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Hose cover 1
2 Brake hose holder 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8 Caliper 1
9 Brake lever 1
10 Master cylinder bracket 1
11 Master cylinder 1
2
3
1
3
2

5 - 12
CHAS
EC5A8100
REAR BRAKE
Extent of removal:1 Master cylinder removal2 Brake hose removal
3 Caliper removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR BRAKE REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake pedal 1
2 Master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8Caliper
1
3
1
321
FRONT BRAKE AND REAR BRAKE

5 - 28
CHASFRONT FORK
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:1 Oil seal removal2 Damper rod removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
1 Cap bolt 1 Refer to “REMOVAL POINTS”.
2 Fork spring 1 Drain the fork oil.
3 Dust seal 1
Refer to “REMOVAL POINTS”. 4 Stopper ring 1
5 Inner tube 1
6 Outer tube 1
7 Piston metal 1
8 Slide metal 1
9 Plain washer 1
0 Oil seal 1
A Spring guide 1
B Base valve 1 Use special tool.
C Damper rod 1 Refer to “REMOVAL POINTS”.
1
2