engine oil YAMAHA WR 450F 2003 Service Manual

4 - 80
ENGAC MAGNETO AND STARTER CLUTCH
2. Install:
Holder 1
Bolt 2
NOTE:
Pass the pick-up coil lead 3 and AC mag-
neto lead 4 under the holder as shown.
Take care not to catch the AC magneto lead
between crankcase cover ribs.
Apply the sealant to the grommet of the AC
magneto lead.
Quick gasket:
ACC-QUICK-GS-KT
YAMAHA Bond No. 1215:
90890-85505
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
Plain washer 1
Bearing 2
Starter clutch drive gear 3
Starter clutch 4
NOTE:
Apply the engine oil on the plain washer, bear-
ing and starter clutch drive gear inner circum-
ference.
4. Install:
Woodruff key 1
Rotor 2
NOTE:
Clean the tapered portions of the crankshaft
and rotor.
When installing the woodruff key, make sure
that its flat surface a is in parallel with the
crankshaft center line b.
When installing the rotor, align the keyway c
of the rotor with the woodruff key.
c
2 1 1
ba

4 - 81
ENG

5. Install:

Bolt (starter clutch)
1


Plain washer (rotor)

Nut (rotor)
2

NOTE:

Tighten the rotor nut to 65 Nm (6.5 m·kg,
47 ft·lb), loosen and retighten the rotor nut to
65 Nm (6.5 m·kg, 47 ft·lb).
6. Install:

Shaft
1


Bearing
2


Idle gear 2
3

NOTE:

Apply the engine oil on the shaft, bearing and
idle gear inner circumference.
T R..16 Nm (1.6 m · kg, 11 ft · lb)
T R..65 Nm (6.5 m · kg, 47 ft · lb)

7. Install:

Dowel pin

Gasket [crankcase cover (left)]

Crankcase cover (left)
1


Bolt [crankcase cover (left)]
NOTE:

Tighten the bolts in stage, using a crisscross
pattern.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

8. Install:

Shaft
1


Bearing
2


Idle gear 1
3

NOTE:

Apply the engine oil on the shaft, bearing and
idle gear inner circumference.
9. Install:

Cover (idle gear 1)
1


Bolt
2

NOTE:

Install the cover (idle gear 1) with its mark
a
facing upward.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

AC MAGNETO AND STARTER CLUTCH

4 - 83
ENGENGINE REMOVAL
EC4M0000
ENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is no
danger of it falling over.
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.
Carburetor Refer to “CARBURETOR” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Clutch cable and guide Disconnect at the engine side.
Radiator Refer to “RADIATOR” section.
Shift pedal Refer to “AC MAGNETO AND
STARTER CLUTCH” section.
Cylinder head breather hose and
oil tank breather hoseRefer to “CAMSHAFTS” section.
Ignition coil
Disconnect the AC magneto lead.

4 - 84
ENGENGINE REMOVAL
Extent of removal:1 Engine removal
Extent of removal Order Part name Q’ty Remarks
Crankcase cover (left) Refer to “AC MAGNETO AND
STARTER CLUTCH” section for remov-
ing the starter motor lead.
Disconnect the starter motor
lead.Refer to “ELECTRIC STARTING SYS-
TEM” section in the CHAPTER 6.
Negative battery lead Disconnect at the starter motor side.
1 Engine skid plate (front) 1
2 Neutral switch 1
3 Oil hose 2
4 Chain cover 1
5 Nut (drive sprocket) 1
Refer to “REMOVAL POINTS”. 6 Lock washer 1
7 Drive sprocket 1
8 Clip 1
9 Bolt (brake pedal) 1
10 Brake pedal 1
1

4 - 88
ENGENGINE REMOVAL
Drive sprocket
1. Install:
Drive sprocket 1
Drive chain 2
NOTE:
Install the drive sprocket together with the
drive chain.
2. Install:
Lock washer 1
Nut (drive sprocket) 2
NOTE:
Tighten the nut while applying the rear brake.
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)
3. Bend the lock washer tab to lock the nut.
4. Install:
Chain guide
Chain cover 1
Screw (chain cover) 2
5. Install:
O-ring 1
Dowel pin 2
Oil hose 3
Bolt (oil hose) 4
NOTE:
Apply the lithium soap base grease on the O-
ring.
6. Install:
Spring 1
Pin 2
O-ring 3
Neutral switch 4
Screw (neutral switch) 5
NOTE:
Apply the lithium soap base grease on the O-
ring.
21T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
New
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)

4 - 93
ENGCRANKCASE AND CRANKSHAFT
Crankshaft
1. Remove:
Crankshaft 1
Use the crankcase separating tool 2.
CAUTION:
Do not use a hammer to drive out the
crankshaft.
Crankshaft bearing
1. Remove:
Bearing 1
NOTE:
Remove the bearing from the crankcase by
pressing its inner race.
Do not use the removed bearing.
Crankcase separating tool:
YU-1135-A/90890-01135
INSPECTION
Timing chain and timing chain guide
1. Inspect:
Timing chain
Cracks/stiff → Replace the timing chain
and camshaft sprocket as a set.
2. Inspect:
Timing chain guide
Wear/damage → Replace.
EC4N4101
Crankcase
1. Inspect:
Contacting surface a
Scratches → Replace.
Engine mounting boss b, crankcase
Cracks/damage → Replace.
2. Inspect:
Bearing
Rotate inner race with a finger.
Rough spot/seizure → Replace.
3. Inspect:
Oil seal
Wear/damage → Replace.

4 - 97
ENGCRANKCASE AND CRANKSHAFT
5. Install:
Dowel pin 1
O-ring 2
Crankcase (right)
To crankcase (left).
NOTE:
Fit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft ham-
mer.
When installing the crankcase, the connect-
ing rod should be positioned at TDC (top
dead center).
New
6. Tighten:
Hose guide 1
Clutch cable holder 2
Bolt (clutch cable holder)
Bolt (crankcase)
NOTE:
Tighten the crankcase tightening bolts in
stage, using a crisscross pattern.
7. Install:
Oil delivery pipe
O-ring
Bolt (oil delivery pipe)
8. Install:
Timing chain
Timing chain guide (rear)
Bolt (timing chain guide)
9. Remove:
Sealant
Forced out on the cylinder mating surface.
10. Apply:
Engine oil
To the crank pin, bearing and oil deliv-
ery hole.
11. Check:
Crankshaft and transmission operation.
Unsmooth operation → Repair.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4 - 102
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
5. Install:
Shift fork 1 (L) 1
Shift fork 2 (C) 2
Shift fork 3 (R) 3
Shift cam 4
To main axle and drive axle.
NOTE:
Apply the molybdenum disulfide oil on the
shift fork grooves.
Mesh the shift fork #1 (L) with the 4th wheel
gear 5 and #3 (R) with the 5th wheel gear
7 on the drive axle.
Mesh the shift fork #2 (C) with the 3rd pinion
gear 6 on the main axle.
6. Install:
Transmission assembly 1
To crankcase (left) 2.
NOTE:
Apply the engine oil on the bearings and guide
bars.
7. Check:
Shifter operation
Transmission operation
Unsmooth operation → Repair.

5 - 1
CHAS

EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Trip meter cable 1
2 Hose cover 1
3 Bolt (brake hose holder) 2 Only loosening.
4 Bolt (axle holder) 4 Only loosening.
5 Nut (front wheel axle) 1
6 Front wheel axle 1
7 Front wheel 1
8 Trip meter gear unit 1
9 Collar 1
10 Oil seal 1
11 Bearing 2 Refer to “REMOVAL POINTS”.
12 Brake disc 1
2
31
3

5 - 2
CHAS

EC598100
REAR WHEEL
Extent of removal:
1
Rear wheel removal
2
Wheel bearing removal
3
Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
REAR WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Driven sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3

FRONT WHEEL AND REAR WHEEL