brake YAMAHA WR 450F 2006 Notices Demploi (in French)
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2006, Model line: WR 450F, Model: YAMAHA WR 450F 2006Pages: 786, PDF Size: 22.49 MB
Page 22 of 786
CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS ..................................4-1
EXHAUST PIPE
AND SILENCER ........................................4-3
RADIATOR ................................................4-5
CARBURETOR ..........................................4-8
AIR INDUCTION SYSTEM ......................4-21
CAMSHAFTS ...........................................4-23
CYLINDER HEAD ....................................4-32
VALVES AND VALVE SPRINGS ............4-36
CYLINDER AND PISTON ........................4-45
CLUTCH ...................................................4-51
OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT) .....4-58
BALANCER .............................................4-65
OIL PUMP ................................................4-68
KICK AXLE AND SHIFT SHAFT .............4-72
AC MAGNETO
AND STARTER CLUTCH ........................4-79
ENGINE REMOVAL .................................4-86
CRANKCASE AND CRANKSHAFT ........4-92
TRANSMISSION, SHIFT CAM
AND SHIFT FORK .................................4-101
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL .......5-1
FRONT BRAKE AND REAR BRAKE .....5-10
FRONT FORK ..........................................5-26
HANDLEBAR ...........................................5-39
STEERING ...............................................5-46
SWINGARM .............................................5-53
REAR SHOCK ABSORBER ....................5-61
Page 26 of 786
GEN
INFO
1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Hot starter lever
3“ENGINE STOP” button
4Multi-function display
5Main switch
6Start switch
7Front brake lever
8Throttle grip
9Radiator cap
0Fuel tank cap
ATaillight
BKickstarter
CFuel tank
DHeadlight
ERadiator
FCoolant drain bolt
GRear brake pedal
HValve joint
IFuel cock
JCold starter knob
KAir cleaner
LDrive chain
MShift pedal
NOil dipstick
OFront forkNOTE:
The machine you have purchased may differ
slightly from those shown in the following.
Designs and specifications are subject to
change without notice.
A
BCD
E
F G
1234
5
6
7
8
9 0
HI
J
K
L M
N O
Page 52 of 786
1 - 11
GEN
INFO
CONTROL FUNCTIONS
EC152000
CLUTCH LEVER
The clutch lever 1 is located on the left han-
dlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disen-
gage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
EC153000
SHIFT PEDAL
The gear ratios of the constant-mesh 5 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
EC154000
KICKSTARTER
Rotate the kickstarter 1 away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kickstarter so the engine can be
started in any gear if the clutch is disengaged.
In normal practices, however, shift to neutral
before starting.
1
EC155001
THROTTLE GRIP
The throttle grip 1 is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.
EC156000
FRONT BRAKE LEVER
The front brake lever 1 is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
Page 54 of 786
1 - 12
GEN
INFO
CONTROL FUNCTIONS
EC157000
REAR BRAKE PEDAL
The rear brake pedal 1 is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.
FUEL COCK
The fuel cock supplies fuel from the tank to
carburetor and also filters the fuel. The fuel
cock has three positions:
OFF: With the lever in this position fuel will
not flow. Always return the lever to this
position when the engine is not running.
ON: With the lever in this position fuel flows
to the carburetor. Normal riding is done
with the lever in this position.
RES: With the lever in this position fuel flows
to the carburetor from the reserve sec-
tion of the fuel tank after the main sup-
ply of the fuel has been depleted.
Normal riding is possible with the lever
is in this position, but it is recommended
to add fuel as soon as possible.
COLD STARTER KNOB
When cold, the engine requires a richer air-fuel
mixture for starting. A separate starter circuit,
which is controlled by the cold starter knob 1,
supplies this mixture. Pull the cold starter knob
out to open the circuit for starting. When the
engine has warmed up, push it in to close the
circuit.
HOT STARTER LEVER
The hot starter lever 1 is used when starting a
warm engine.
Use the hot starter lever when starting the
engine again immediately after it was stopped
(the engine is still warm). Pulling the hot starter
lever injects secondary air to thin the air-fuel
mixture temporarily, allowing the engine to be
started more easily.
Page 82 of 786
GEN
INFO
1 - 26
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.
Frame to rear frame
Fuel tank to frame
Silencer to rear frame
Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering shaft to frame
Steering shaft to handle crown
Handle crown to handlebar
Front fork to handle crown
Front fork to under bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of front axle
Tightening of axle holder
Tightening of rear axle
Wheel to sprocket
Caliper to front fork
Brake disc to wheel
Tightening of union bolt
Master cylinder to handlebar
Tightening of air bleeder
Tightening of brake hose holder
Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Master cylinder to frame
Tightening of air bleeder
Tightening of brake hose holder
Fuel tank to fuel cock
Tightening of oil hose clamp Frame construction
Combined seat and tank
Exhaust system
Engine mounting
Steering Steering shaft to
handlebar
Suspension Front Steering shaft to front
fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of
swingarm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel system
Lubrication system
Page 86 of 786
1 - 27
GEN
INFO
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com-
ponents.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprock-
ets, or wheel axles.
3. Rinse the dirt and degreaser off with a gar-
den hose; use only enough pressure to do
the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel
and lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.
Page 92 of 786
SPEC
2 - 3 Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 305 mm (12.0 in)
Electrical:
Ignition system CDI
Generator system AC magneto
Battery type YTZ7S
Battery voltage/capacity 12 V/6 AH
Specific gravity 1.310
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity:
Headlight 12 V 60/55 W × 1
Taillight 12 V 21/5 W × 1
GENERAL SPECIFICATIONS
Page 103 of 786
SPEC
2 - 14 Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 21 × 1.60/Aluminum ----
Rear rim size/material 18 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm
(0.08 in)
Lateral ---- 2.0 mm
(0.08 in)
Drive chain:
Type/manufacturer DID520VM/DAIDO ----
Number of links 113 links + joint ----
Chain slack 48 ~ 58 mm (1.9 ~ 2.3 in) ----
Chain length (15 links) ---- 239.3 mm
(9.42 in)
Front disc brake:
Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in)
250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in)
245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)5 mm (0.20 in) ----
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit
MAINTENANCE SPECIFICATIONS
Page 104 of 786
SPEC
2 - 15
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m kg, 27 ft lb) by using the ring nut
wrench, then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m kg, 5.1 ft lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Handle crown and outer tube M8 × 1.25 4 23 2.3 17
Under bracket and outer tube M8 × 1.25 4 20 2.0 14
Handle crown and steering shaft M24 × 1.0 1 145 14.5 105
Handlebar holder (upper) M8 × 1.25 4 28 2.8 20
Handlebar holder (lower) M12 × 1.25 2 40 4.0 29
Steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M51 × 1.5 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21
Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and protector M6 × 1.0 6 7 0.7 5.1
Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1
Throttle cable cap M5 × 0.8 2 4 0.4 2.9
Clutch lever holder mounting M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting M6 × 1.0 1 4 0.4 2.9
Hot starter lever holder mounting M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting M5 × 0.8 1 2 0.2 1.4
Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3
Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Hose guide (front brake hose) and hose guide bracketM5 × 0.8 1 4 0.4 2.9
Hose guide (front brake hose) and under bracketM6 × 1.0 1 4 0.4 2.9
Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Front brake caliper and front fork M8 × 1.25 2 23 2.3 17
Front brake caliper and brake hose holder M6 × 1.0 1 10 1.0 7.2
Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2
Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13
Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3
Front wheel axle and nut M16 × 1.5 1 90 9.0 65
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
Brake pedal mounting M8 × 1.25 1 26 2.6 19
Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
MAINTENANCE SPECIFICATIONS
Page 105 of 786
SPEC
2 - 16 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Rear wheel axle and nut M20 × 1.5 1 125 12.5 90
Driven sprocket and wheel hub M8 × 1.25 6 50 5.0 36
Nipple (spoke)—72 3 0.3 2.2
Disc cover and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11
Engine mounting:
Engine upper bracket and frame M10 × 1.25 2 55 5.5 40
Engine lower bracket and frame M8 × 1.25 4 34 3.4 24
Engine and engine bracket (front) M10 × 1.25 1 69 6.9 50
Engine and engine bracket (upper) M10 × 1.25 1 52 5.2 37
Engine and frame (lower) M10 × 1.25 1 69 6.9 50
Engine guard (left and right) M8 × 1.25 2 23 2.3 17
Engine skid plate mounting (front) M6 × 1.0 3 10 1.0 7.2
Engine skid plate mounting (rear) M6 × 1.0 3 10 1.0 7.2
Regulator mounting M6 × 1.0 2 7 0.7 5.1
Pivot shaft and nut M16 × 1.5 1 80 8.0 58
Relay arm and swingarm M14 × 1.5 1 70 7.0 50
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame and frame (upper) M8 × 1.25 1 32 3.2 23
Rear frame and frame (lower) M8 × 1.25 2 29 2.9 21
Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Drive chain tensioner mounting (upper) M8 × 1.25 1 19 1.9 13
Drive chain tensioner mounting (lower) M8 × 1.25 1 20 2.0 14
Chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank mounting M6 × 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 × 1.0 2 6 0.6 4.3
Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1
Fuel tank and hooking screw (fitting band) M6 × 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Seat mounting M8 × 1.25 2 23 2.3 17
Side cover mounting M6 × 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
Air scoop and radiator panel (lower) M6 × 1.0 2 6 0.6 4.3
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting (front) M6 × 1.0 2 7 0.7 5.1
Rear fender mounting (rear) M6 × 1.0 2 11 1.1 8.0
Multi-function display bracket mounting M6 × 1.0 2 7 0.7 5.1
MAINTENANCE SPECIFICATIONS