set clock YAMAHA WR 450F 2005 Owners Manual

SPEC
2 - 6 Valve spring:
Free length IN 37.03 mm (1.46 in) 36.03 mm
(1.42 in)
EX 37.68 mm (1.48 in) 36.68 mm
(1.44 in)
Set length (valve closed) IN 27.87 mm (1.10 in) ----
EX 27.38 mm (1.08 in) ----
Compressed force
(installed) IN 111.3 ~ 127.9 N at 27.87 mm
(11.3 ~ 13.0 kg at 27.87 mm,
24.91 ~ 28.66 lb at 1.10 in)----
EX 127.4 ~ 146.4 N at 27.38 mm
(13.0 ~ 14.9 kg at 27.38 mm,
28.66 ~ 32.85 lb at 1.08 in)----
Tilt limit IN ----
2.5°/ 1.61 mm
(2.5°/0.063 in)
EX ----2.5°/1.65 mm
(2.5°/0.065 in)
Direction of winding (top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)0.1 mm
(0.004 in)
Piston size “D”94.945 ~ 94.960 mm
(3.738 ~ 3.739 in)----
Measuring point “H”8 mm (0.315 in) ----
Piston off-set 1 mm (0.0394 in) ----
Piston pin bore inside diameter 18.004 ~ 18.015 mm
(0.7088 ~ 0.7093 in)18.045 mm
(0.7104 in)
Piston pin outside diameter 17.991 ~ 18.000 mm
(0.7083 ~ 0.7087 in)17.971 mm
(0.7075 in) Item Standard Limit
*
H
D
MAINTENANCE SPECIFICATIONS

3 - 5
INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap
1, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:
Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Inspect:
Coolant level
Coolant level should be between the
maximum a and minimum b marks.
Coolant level is below the “LOW” level
line → Add soft water (tap water) up to
the proper level.
3. Start the engine and let it warm up for sev-
eral minutes.
4. Turn off the engine and check the coolant
level again.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant settles.
a
b
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap when the
engine is hot.
ENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT

3 - 22
INSP
ADJ
6. Install:
All removed parts
NOTE:
Install all removed parts in reversed order of
their removal.Locate the rounded-off value and the mea-
sured valve clearance in the chart “PAD
SELECTION TABLE”. The field where
these two coordinates intersect shows the
new pad number to use.
NOTE:
Use the new pad number only as a guide
when verifying the valve clearance adjust-
ment.
Install the new pads 6 and the valve lift-
ers 7.
NOTE:
Apply the engine oil on the valve lifters.
Apply the molybdenum disulfide oil on the
valve stem ends.
Valve lifter must turn smoothly when
rotated with a finger.
Be careful to reinstall valve lifters and
pads in their original place.
Install the camshafts (exhaust and intake),
the timing chain and the camshaft caps.
Refer to “CAMSHAFTS” section in the
CHAPTER 4.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m  kg, 7.2 ft  lb)
Install the timing chain tensioner.
Refer to “CAMSHAFTS” section in the
CHAPTER 4.
NOTE:
Turn the crankshaft counterclockwise sev-
eral turns so that the installed parts settle
into the right position.
Recheck the valve clearance.
If the clearance is still incorrect, repeat all
the clearance adjustment steps until the
specified clearance is obtained.
VALVE CLEARANCE ADJUSTMENT

7 - 19
TUNSETTING
EC72H002
Suspension setting
Front fork
NOTE:
If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.
Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm
(3.5 ~ 3.9 in).
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff over entire rangeCompression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil level (oil amount) Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Spring Replace with soft spring.
Unsmooth movement
over entire rangeOuter tube
Check for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Inner tube
Under bracket tightening
torqueRetighten to specified torque.
Poor initial
movementRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil seal Apply grease in oil seal wall.
Soft over entire
range, bottoming outCompression damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Oil level (oil amount) Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Spring Replace with stiff spring.
Stiff toward stroke
endOil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke
end, bottoming outOil level (oil amount) Increase oil level by about 5 mm (0.2 in).
Stiff initial movement Compression dampingTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low front, tending to
lower front postureCompression damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in)
when one passenger is astride seat (lower rear pos-
ture).
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
“Obtrusive” front,
tending to upper front
postureCompression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in)
when one passenger is astride seat (upper rear pos-
ture).
Spring Replace with soft spring.
Oil lever (oil amount) Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).

7 - 20
TUNSETTING
Rear shock absorber
NOTE:
If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.
Adjust the rebound damping in 2-click increments or decrements.
Adjust the low compression damping in 1-click increments or decrements.
Adjust the high compression damping in 1/6 turn increments or decrements.
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff, tending to sinkRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in)
when one passenger is astride seat.
Spongy and unstableRebound damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Low compression damp-
ingTurn adjuster clockwise (about 1 click) to increase
damping.
Spring Replace with stiff spring.
Heavy and draggingRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Spring Replace with soft spring.
Poor road grippingRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low compression damp-
ingTurn adjuster clockwise (about 1 clicks) to increase
damping.
High compression damp-
ingTurn adjuster clockwise (about 1/6 clicks) to
increase damping.
Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in)
when one passenger is astride seat.
Spring Replace with soft spring.
Bottoming outHigh compression damp-
ingTurn adjuster clockwise (about 1/6 turn) to increase
damping.
Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in)
when one passenger in astride seat.
Spring Replace with stiff spring.
BouncingRebound damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Spring Replace with soft spring.
Stiff travelHigh compression damp-
ingTurn adjuster counterclockwise (about 1/6 turn) to
decrease damping.
Spring set length Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in)
when one passenger is astride seat.
Spring Replace with soft spring.