fuse YAMAHA WR 450F 2004 Owners Manual

SPEC
2 - 19
MAINTENANCE SPECIFICATIONS
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). Starter relay:
Model/manufacturer 2768090-A/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221 M06/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 ˚C (68 ˚F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M5 × 0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5 × 0.8 2 7 0.7 5.1
Rotor M12 × 1.25 1 Refer to NOTE.
Neutral switch M5 × 0.8 2 4 0.4 2.9
Starter motor M6 × 1.0 2 10 1.0 7.2
Starter relay terminal M6 × 1.0 2 4 0.4 2.9 Item Standard Limit

2 - 7
CARACTERISTIQUES D’ENTRETIEN
SPEC

Segment:
Segment de feu:
Type Cylindrique ----
Dimensions (B
×
T) 1,2
×
3,5 mm (0,05
×
0,14 in) ----
Ecartement des becs (monté) 0,20 à 0,30 mm
(0,008 à 0,012 in)0,55 mm
(0,022 in)
Jeu latéral (monté) 0,030 à 0,065 mm
(0,0012 à 0,0026 in)0,12 mm
(0,005 in)
Segment d’étanchéité:
Type Fuselé----
Dimensions (B
×
T) 1,00
×
3,35 mm (0,04
×
0,13 in) ----
Ecartement des becs (monté) 0,35 à 0,50 mm
(0,014 à 0,020 in)0,85 mm
(0,033 in)
Jeu latéral 0,020 à 0,055 mm
(0,0008 à 0,0022 in)0,12 mm
(0,005 in)
Segment racleur d’huile:
Dimensions (B
×
T) 2,0
×
2,9 mm (0,08
×
0,11 in) ----
Ecartement des becs (monté) 0,2 à 0,5 mm (0,01 à 0,02 in) ----
Vilebrequin:
Largeur du vilebrequin “A”61,95 à 62,00 mm
(2,439 à 2,441 in)----
Limite de déflexion “C”0,03 mm (0,0012 in) 0,05 mm
(0,002 in)
Jeu latéral de tête de bielle “D”0,15 à 0,45 mm
(0,0059 à 0,0177 in)0,50 mm
(0,02 in)
Déflexion de pied de bielle “F”0,4 à 1,0 mm
(0,02 à 0,04 in)2,0 mm
(0,08 in)
Dispositif d’équilibrage:
Type d’entraînement du dispositif Engrenage ----
Type d’huile du filtre à air: Huile de filtre à air en mousse ou
huile équivalente---- Article Standard Limite
T
B
B
T
B
T

3 - 56
INSP
ADJ
FUSE INSPECTION
6. Install:
Battery
Battery band
7. Connect:
Battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1, then the
negative lead 2.
8. Check:
Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
Battery terminal
10. Install:
Seat
EAS00181
FUSE INSPECTION
CAUTION:
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
Seat
Fuse cover
2. Check:
Continuity
2Reserve fuse
Recommended lubricant
Lithium soap base grease
Checking steps:
Remove the fuse 1.
Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester
YU-3112-C/90890-03112
If the pocket tester indicates “∞”, replace
the fuse.
2
1

3 - 57
INSP
ADJ
REPLACING THE HEADLIGHT BULBS
3. Replace:
Blown fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the starting and
ignition systems to malfunction and could
possibly cause a fire.
4. Install:
Fuse cover
Seat Replacement steps:
Set the main switch to “OFF”.
Install a new fuse of the correct amperage.
Set on the switches to verify if the electri-
cal circuit is operational.
If the fuse immediately blows again, check
the electrical circuit.
ItemsAmperage
ratingQ’ty
Main fuse 10 A 1
REPLACING THE HEADLIGHT BULBS
1. Remove:
Headlight
Refer to “SEAT, FUEL TANK AND
SIDE COVERS” section in the CHAP-
TER 4.
2. Remove:
Headlight bulb holder cover 1
3. Detach:
Headlight bulb holder 1
4. Remove:
Headlight bulb 2
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb unit it has cooled
down.

6 - 1
–+ELEC

ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1
Headlight
2
“ENGINE STOP”
button
3
Clutch switch
4
Diode
5
Starter relay diode
6
TPS (throttle posi-
tion sensor)
7
Starter relay
8
Fuse
9
Starting circuit
cut-off relay
0
Taillight
A
Neutral switch
B
Starter motor
C
AC magneto
D
Rectifier/regulator
E
Ignition coil
F
Spark plug
G
Start switch
H
Main switch
I
CDI unit
J
Battery
COLOR CODE
B.......................Black
Br .....................Brown
Gy ....................Gray
L .......................Blue
O ......................Orange
R ......................Red
Sb.....................Sky blue
W......................White
Y.......................Yellow
B/L....................Black/Blue
EC612000
WIRING DIAGRAM
1 2345
678
90
A B
CDEFGH
I
J
WR
WR
R
BR/BBr
R
BR/BBr
RW
L/RL/BBB
SbL/W
WY
YW
L/YBBB
WY
RYW
R
LY
B
YLB/L
B
B
ON
OFF
10A
BB
OFF
STARTSTART
R-BrL/W
B
BrL/W
BrL/W
L/B
-YB
YL
B
L-B
L/WSb
B/WBBB
W/RB/W
R/BGyBrL/W
ON
STOP
OB
LYSbB/L
W RBrB/W
L/BGyWR/B
B O
L/YSbL/R
R W
Y W
Y W
Y
L B
B
B
RRR/B
B Br B
B B B B
L/W
R
R
R R B
R
BrBr
L/W L/W
Br B
L/B
L/B
L/R

Br
R/B
L/B L/W
B/W
W W/RW
RO
L
Y
B/L
O

B
L
Y
B/LSbL/WB/W
B
L/R L/Y L/Y
B
SbSbL/W
BGy
SbBB/LYO
L
*2
O B
L YL/W
B/L
*1
CD
BI
5
9
G3 4
A 2J
EF
6 7
K8
1
0
*
2
*1
*2: Except for USA
*1: For USA

B/W .................. Black/White
L/B ................... Blue/Black
L/R ................... Blue/Red
L/Y ................... Blue/Yellow
L/W .................. Blue/White
R/B................... Red/Black

–+ELEC

6 - 3
IGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Only when the ignition checker is used.
NOTE:


Remove the following parts before inspection.
1) Seat
2) Fuel tank

Use the following special tools in this inspection.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112
*1 Check fuse.Replace fuse and
check wire harness.
*2 Check battery Recharge or replace.
Spark gap test*3 Clean or replace
spark plug.
Check entire ignition
system for connection.
(couplers, leads and
ignition coil)Repair or replace.
Check “ENGINE STOP”
button.Replace.
Check main switch. Replace.
Check ignition coil. Primary coil Replace.
Secondary coil Replace.
Check AC magneto. Pick-up coil Replace.
Check neutral switch. Repair or replace.
Replace CDI unit.
OK
OK
No spark
OK
OK
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good
No good
No good
No good

6 - 7
–+ELEC
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the main switch is set to “ON”, the starter
motor can only operate if at least one of the
following conditions is met:
The transmission is in neutral (the neutral
switch is closed).
The clutch lever is pulled to the handlebar
(the clutch switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when neither of
these conditions has been met. In this
instance, the starting circuit cut-off relay is
open so current cannot reach the starter
motor. When at least one of the above condi-
tions has been met the starting circuit cut-off
relay is closed and the engine can be started
by pressing the start switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR
1Battery
2Main fuse
3Main switch
4Starting circuit cut-off relay
5Start switch
6Diode
7Clutch switch
8Neutral switch
9Starter relay
0Starter motor
12
M
3
4
5
8 76 9
0
ELECTRIC STARTING SYSTEM

–+ELEC
6 - 8
ELECTRIC STARTING SYSTEM
INSPECTION STEPS
If the starter motor will not operate, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Refer to “MAIN SWITCH INSPECTION” section.
*4 marked: Refer to “NEUTRAL SWITCH INSPECTION” section.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Rear fender
Use 12 V battery in this inspection.
Use the following special tools in this inspection.
Pocket tester:
YU-3112-C/90890-03112
*1 Check fuseReplace fuse and
check wire harness.
*2 Check battery Recharge or replace.
Check each coupler and
wire connection.Repair or replace.
*3 Check main switch. Replace.
Check starter motor
operation.Repair or replace.
Check starting circuit
cut-off relay.Replace.
Check starter relay. Replace.
*4 Check neutral switch. Replace.
Check clutch switch. Replace.
Check diode. Replace.
Check start switch. Replace.
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good

–+ELEC
6 - 17
CHARGING SYSTEM
EC680000
CHARGING SYSTEM
EC681001
INSPECTION STEPS
If the battery is not charged, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Fuel tank
Use the following special tool in this inspection.
Pocket tester:
YU-3112-C/90890-03112
*1 Check fuse.Replace fuse and
check wire harness.
*2 Check battery. Recharge or replace.
Check each coupler and
wire connection.Repair or replace.
Check charging voltage.Charging system is
good.
Check AC magneto. Charging coil Replace.
Replace rectifier/regulator.
OK
OK
OK
No good
OK
No good
No good
No good
No good
OK

TUN
REGLAGE
EINSTELLUNG
AJUSTE
Düsennadel einstellen
Die Düsennadel wird eingestellt,
indem sie ausgetauscht wird.
* Nicht USA
Der konische Teil hat bei jeder
Düsennadel für dieses Modell die-
selbe Länge; die Nadeln sind aber in
Ausführungen mit unterschiedlichen
Durchmessern des geraden Teils
erhältlich.Standard-
DüsennadelOBDWR
* OBDUQ

OBDWR - 4
Clip-Position
Durchmesser a des
geraden Teils
Wirkung des Austausch
s der Düsennadel
(Durchmesser des geraden Teils)
Der Durchmesser des geraden Teils
beeinflußt das Luft-Kraftstoff-
Gemisch bei 1/8–1/4 geöffnetem
Gasdrehgriff.
ÅLeerlaufıVollgas
Zusammenhang mit der Gasdreh-
grifföffnung
Die durch das Vergaser-Hauptsy-
stem strömende Luftmenge wird
durch die Hauptdüse geregelt und
danach weiter durch die Fläche zwi-
schen der Hauptdüse und der
Düsennadel kontrolliert.
Der Kraftstofffluß entspricht bei etwa
1/8–1/4 geöffnetem Gasdrehgriff
dem Durchmesser des geraden Teils
der Düsennadel, bei etwa 1/8–3/4
geöffnetem Gasdrehgriff dagegen
der Düsennadel-Clip-Position.
Daher wird der Kraftstofffluß an jeder
Stufe der Gasdrehgrifföffnung durch
die Kombination des Durchmessers
des geraden Teils der Düsennadel
und der Düsennadel-Clip-Position
ausgeglichen.
1/4 1/2 3/4
+10%
R
–10%
Q
S
Åı
Réglage de l’aiguille
L’aiguille se règle en la changeant.
* Excepté USA
La longueur de la partie conique des
aiguilles destinées à cette machine est
fixe, mais le diamètre de la partie droite
diffèrent selon les aiguilles. Aiguille standardOBDWR
* OBDUQ

OBDWR - 4
Position du clip
Diamètre a de la par-
tie droite
Effets du changement d’aiguille (réfé-
rence)
(Diamètre de la partie droite)
Une modification du diamètre de la par-
tie droite modifie l’émulsion air-essence
à une ouverture des gaz de 1/8 à 1/4.
ÅRalentiıComplètement ouvert
Rapport avec l’ouverture des gaz
Le débit d’essence dans le circuit princi-
pal du carburateur est contrôlé par le
gicleur principal ainsi que par la distance
entre le diffuseur et l’aiguille.
Le débit dépend du diamètre de la por-
tion droite de l’aiguille à une ouverture
des gaz de 1/8 à 1/4 et dépend de la posi-
tion du clip à une ouverture des gaz de 1/
8 à 3/4.
Le débit d’essence est réglé à chaque
degré d’ouverture des gaz par une com-
binaison des facteurs suivants: diamètre
de la partie droite de l’aiguille et position
du clip.
1/4 1/2 3/4
+10%
R
–10%
Q
S
Åı
7 - 7
Ajuste de la aguja del surtidor
La aguja del surtidor se ajusta cambián-
dola.
* Excepto para USA
Las partes cónicas de todas las agujas del
surtidor tienen las mismas posiciones de
arranque pero las agujas están disponi-
bles con diferentes diámetros de partes
rectas.Aguja del surtidor
estándarOBDWR
* OBDUQ

OBDWR - 4
Posición del clip
Diámetro a de la parte
recta
Efectos del cambio de la aguja del sur-
tidor (referencia)
(Diámetro de la parte recta)
Al cambiar el diámetro de la parte recta
se ajusta la mezcla de aire y combustible
cuando el acelerador tiene una abertura
de 1/8 a 1/4.
ÅRalentíıCompletamente abierto
Relación con la abertura del acelerador
La circulación del combustible a través
del sistema principal del carburador es
controlada por el surtidor principal para
después ser regulada por la zona exis-
tente entre la boquilla principal y la
aguja del surtidor.
La circulación del combustible está rela-
cionada con el diámetro de la parte recta
de la aguja del surtidor con una abertura
del acelerador de 1/8 a 1/4 y la posición
del clip con una abertura del acelerador
de 1/8 a 3/4.
Por tanto, la circulación del combustible
está equilibrada en cada etapa de aber-
tura del acelerador mediante la combina-
ción del diámetro de la parte recta de la
aguja del surtidor y la posición del clip.
1/4 1/2 3/4
+10%
R
–10%
Q
S
Åı