engine YAMAHA WR 450F 2006 Manuale de Empleo (in Spanish)

SPEC
2 - 20
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm mkg ftlb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg
× m/sec
2 Force
Nm
m  kgNewton meter
Meter kilogramN
× m
m
× kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute
—Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS

2 - 28
SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Clamp
3Brake hose
4Hot starter cable
5Clutch cable
6Hose guide
7Speed sensor lead
8Main switch lead
9Main switch
0Multi-function display
AStart switch lead
BClutch switch lead
C“ENGINE STOP” button lead
DMulti-function display leadÈFasten the start switch lead to
the handlebar with the plastic
bands.
ÉFasten the “ENGINE STOP”
button lead and clutch switch
lead to the handlebar with the
plastic bands.
ÊPass the brake hose through
the hose guides.
ËSecure the coupler by inserting
it into the multi-function display
bracket.
ÌPass the main switch lead
above the multi-function display
bracket.
ÍPass the throttle cables, clutch
cable and hot starter cable
between the handle crown and
multi-function display.ÎPass the multi-function display
lead and speed sensor lead
between the multi-function dis-
play and the multi-function dis-
play bracket.
ÏSecure the coupler by pushing
it into the hole in the multi-func-
tion display bracket.
ÐFasten the clutch switch lead
and “ENGINE STOP” button
lead to the multi-function dis-
play bracket and cut off the tie
end. Fasten them at a location
where the tie end does not con-
tact the multi-function display.
ÑSecure the wire harness clip by
pushing it into the hole in the
multi-function display bracket
on the inside.
4
5
Î
Ê Ó
A
B
F-FE-E
C
D
A
D
7
7
Ò ËA
12
È32
É
6
Ê
6
8
Ì0
9
ËÑ C
BÏ
2
Ð 8
8
1Í
4
5
4
5B2
C
DC BB A
F F
EE
EE
Ë
2

2 - 28
SPEC
1Gaszug
2Kabelbinder
3Bremsschlauch
4Warmstartzug
5Kupplungszug
6Schlauchführung
7Geschwindigkeitssensor-Kabel
8Zündschalter-Kabel
9Zündschalter
0Multifunktionsanzeige
AStarterschalter-Kabel
BKupplungsschalter-Kabel
CKabel des Motorstoppschalters
“ENGINE STOP”
DMultifunktionsanzeigen-Kabel
ÈDas Starter-Kabel mit Kunststoffbin-
dern am Lenker befestigen.
ÉDie Motorstoppschalter- und Kupp-
lungsschalter-Kabel mit Kunststoffbin-
dern am Lenker befestigen.
ÊDen Bremsschlauch durch die
Schlauchführungen leiten.
ËDen Steckverbinder in die Multifunkti-
onsanzeigen-Halterung einsetzen und
sichern.
ÌDas Zündschloss-Kabel über der Mul-
tifunktionsanzeigen-Halterung ent-
lang verlegen.
ÍDie Gaszüge, den Kupplungs- und
Heißstartzug zwischen der oberen
Gabelbrücke und der Multifunktions-
anzeige verlegen.
ÎDas Multifunktionsanzeigen-Kabel
und das Geschwindigkeitssensor-
Kabel zwischen der Multifunktionsan-
zeige und der Multifunktionsanzeigen-
Halterung verlegen.
ÏDen Steckverbinder in die Öffnung in
der Multifunktionsanzeigen-Halterung
drücken, um ihn zu sichern.
ÐDas Kupplungsschalter-Kabel und
das “ENGINE STOP”-Schalterkabel
an der Multifunktionsanzeigen-Halte-
rung befestigen und dann das Ende
des Kabelbinders abschneiden. Diese
an einer Stelle befestigen, an der das
Kabelbinderende nicht die Multifunkti-
onsanzeige berührt.
ÑDen Kabelbaum-Clip von innen in die
Öffnung der Multifunktionsanzeigen-
Halterung drücken, um ihn zu sichern. 1Câble des gaz
2Collier à pince
3Durit de frein
4Câble de démarrage à chaud
5Câble d’embrayage
6Guide de durit
7Fil du capteur de vitesse
8Fil du contacteur à clé
9Contacteur à clé
0Ecran multifonction
AFil du contacteur du démarreur
BFil du contacteur d’embrayage
CFil du bouton “ENGINE STOP”
DFil de l’écran multifonction
ÈFixer le fil du contacteur de démarrage au
guidon à l’aide des bandes en plastique.
ÉFixer le fil du bouton “ENGINE STOP”
et le fil du contacteur d’embrayage au
guidon à l’aide de bandes en plastique.
ÊAcheminer la durit de frein dans les gui-
des de durit.
ËFixer la fiche rapide en l’insérant dans le
support de l’écran multifonction.
ÌPasser le fil du contacteur à clé au-dessus
du support de l’écran multifonction.
ÍPasser les câbles des gaz, le câble
d’embrayage et le câble du démarreur à
chaud entre la couronne de poignée et
l’écran multifonction.
ÎPasser le fil de l’écran multifonction et
celui du capteur de vitesse entre l’écran
multifonction et son support.
ÏFixer la fiche rapide en l’enfonçant dans
l’orifice du support de l’écran multifonc-
tion.
ÐFixer le fil du contacteur d’embrayage et
celui du bouton “ENGINE STOP” sur le
support de l’écran multifonction et couper
l’extrémité du collier. Les fixer à un
endroit où l’extrémité du collier n’entre
pas en contact avec l’écran multifonction.
ÑFixer le clip du faisceau de fils en l’enfon-
çant dans l’orifice du support de l’écran
multifonction à l’intérieur.1Cable del acelerador
2Brida
3Tubo de freno
4Cable de arranque en caliente
5Cable de embrague
6Guía de tubo
7Cable del sensor de velocidad
8Cable del interruptor principal
9Interruptor principal
0Visor multifunción
ACable del interruptor de arranque
BCable del interruptor del embrague
CCable del botón “ENGINE STOP” (paro
del motor)
DCable del visor multifunción
ÈSujete el cable del interruptor de arranque
al manillar con las bandas de plástico.
ÉSujete el cable del botón “ENGINE
STOP” y el cable del interruptor del
embrague al manillar con las bandas de
plástico.
ÊPase el tubo de freno por las guías.
ËSujete el acoplador introduciéndolo en el
soporte del visor multifunción.
ÌPase el cable del interruptor principal por
encima del soporte del visor multifunción.
ÍPase los cables del acelerador, el cable de
embrague y el cable de arranque en
caliente entre la corona del manillar y el
visor multifunción.
ÎPase cable del visor multifunción y el
cable del sensor de velocidad entre el
visor multifunción y el soporte de este.
ÏSujete el acoplador empujándolo al inte-
rior del orificio del soporte del visor mul-
tifunción.
ÐSujete el cable del interruptor del embra-
gue y el cable del botón de “ENGINE
STOP” al soporte del visor multifunción y
corte el extremo de la abrazadera. Sujéte-
los en un lugar en que el extremo de la
abrazadera no toque el visor multifunción.
ÑSujete el clip del mazo de cables empu-
jándolo al interior del orificio del soporte
del visor multifunción por el lado interior.
DIAGRAMME D’ACHEMINEMENT DES CABLES
KABELFÜHRUNGSDIAGRAMME
DIAGRAMA DE CABLEADO

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
ENGINE OIL
Replace
VALVES
The engine must be cold.
Check the valve seats
and valve stems for wear. Check the valve clearances
Inspect
Replace
VALVE SPRINGS
Check the free length and
the tilt. Inspect
Replace
VALVE LIFTERS
Check for scratches and
wear. Inspect
Replace
CAMSHAFTS Inspect the camshaft sur-
face.
Inspect the decompres-
sion system Inspect
Replace
CAMSHAFT SPROCKETS
Check for wear on the
teeth and for damage. Inspect
Replace
PISTON
Inspect crack
Inspect carbon deposits
and eliminate them. Inspect
Clean
Replace
PISTON RING
Check ring end gap Inspect
Replace
PISTON PIN
Inspect
Replace
CYLINDER HEAD Inspect carbon deposits
and eliminate them.
Change gasket Inspect and clean
CYLINDER
Inspect and clean
Inspect score marks
Inspect wear
Replace
CLUTCH
Inspect housing, friction
plate, clutch plate and
spring Inspect and adjust
Replace
TRANSMISSION
Inspect
Replace bearing
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-21
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-14 ~ 18
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-10
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10 ~ 11
Brakes Check the play of front brake and effect of front and rear brake. P.3-25 ~ 31
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-32 ~ 35
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-43 ~ 44
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-44 ~ 46
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-35 ~ 42
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or when
the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks.—
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-32
Lubrication Check for smooth operation. Lubricate if necessary. P.3-47
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-26
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 20

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 - 6
INSP
ADJ
COOLANT REPLACEMENT
CAUTION:
Take care so that coolant does not splash
on painted surfaces. If it splashes, wash it
away with water.
1. Place a container under the engine.
2. Remove:
Seat
Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
3. Disconnect:
Coolant reservoir hose 1
Drain the coolant completely.
4. Connect:
Coolant reservoir hose
LOWFULLCOOLANT1
5. Remove:
Engine guard 1
Coolant drain bolt 2
6. Remove:
Radiator cap
Drain the coolant completely.
7. Clean:
Cooling system
Thoroughly flush the cooling system with
clean tap water.
8. Install:
Copper washer
Coolant drain bolt
Engine guard
Bolt [engine guard (front)]
Bolt [engine guard (rear)]
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)

3 - 7
INSP
ADJ
COOLANT REPLACEMENT
9. Fill:
Radiator
Engine
To specified level.
CAUTION:
Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
Do not use water containing impurities or
oil.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
anti-corrosion for
aluminum engine
Coolant
1 and water
(soft water)
2 mixing ratio:
50%/50%
Coolant capacity:
1.20 L (1.06 Imp qt, 1.27 US qt)
Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.
When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
10. Install:
Radiator cap
11. Fill:
Coolant reservoir tank
Midway a between maximum and mini-
mum marks on the tank.
LOWFULLCOOLANTa

3 - 8
INSP
ADJRADIATOR CAP INSPECTION/
RADIATOR CAP OPENING PRESSURE INSPECTION
12. Install:
Coolant reservoir cap
13. Start the engine and let it warm up for sev-
eral minutes.
14. Turn off the engine and inspect the coolant
level.
Refer to “COOLANT LEVEL INSPECTION”
section.
NOTE:
Before checking the coolant level wait a few
minutes until the coolant settles.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
Seal (radiator cap) 1
Valve and valve seat 2
Crack/damage → Replace.
Exist fur deposits 3 → Clean or replace.
EC356001
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:
Radiator cap tester 1 and adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/90890-01325
Adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
110 kPa (1.1 kg/cm2, 15.6 psi)

3 - 11
INSP
ADJTHROTTLE LUBRICATION/
HOT STARTER LEVER ADJUSTMENT
THROTTLE LUBRICATION
1. Remove:
Cover (throttle cable cap) 1
Cover (grip cap) 2
Throttle cable cap 3
NOTE:
Before adjusting the throttle cable free play,
the engine idle speed should be adjusted.
WARNING
After adjusting the throttle cable free
play, start the engine and turn the han-
dlebar to right and left and make sure
that the engine idling does not run faster.
2. Apply:
Lithium soap base grease
On the throttle cable end a.
3. Install:
Throttle cable cap
Screw (throttle cable cap)
Cover (grip cap)
Cover (throttle cable cap)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
HOT STARTER LEVER ADJUSTMENT
1. Check:
Hot starter lever free play a
Out of specification → Adjust.
2. Adjust:
Hot starter lever free play
NOTE:
After adjustment, check proper operation of
hot starter.
Hot starter lever free play
a:
3 ~ 6 mm (0.12 ~ 0.24 in)
Hot starter lever free play adjustment
steps:
Loosen the locknut 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknut.