engine YAMAHA WR 450F 2006 Owners Manual

4 - 101
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
TRANSMISSION, SHIFT CAM AND SHIFT FORK
TRANSMISSION, SHIFT CAM AND SHIFT FORK
Extent of removal:
1 Shift fork, shift cam, main axle and drive axle removal
Extent of removal Order Part name Q’ty Remarks
TRANSMISSION, SHIFT CAM
AND SHIFT FORK REMOVAL
Preparation for removal Engine Refer to “ENGINE REMOVAL” section.
Separate the crankcase. Refer to “CRANKCASE AND CRANK-
SHAFT” section.
1 Shift fork 1 1
Refer to “REMOVAL POINTS”. 2 Shift fork 2 1
3 Shift fork 3 1
4Shift cam 1
5 Main axle 1
6 Drive axle 1
7 Collar 1
1

4 - 105
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
FRONT WHEEL REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
1 Bolt (axle holder) 4 Only loosening.
2 Nut (front wheel axle) 1
3 Front wheel axle 1
4 Front wheel 1
5 Speed sensor 1
6 Collar 1
7 Oil seal 1
8 Bearing 2 Refer to “REMOVAL POINTS”.
9 Brake disc 1
2
13
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
REAR WHEEL REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
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”.
10 Brake disc 1
3
3
1
2
FRONT WHEEL AND REAR WHEEL

5 - 10
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000
FRONT BRAKE
Extent of removal:
1 Brake hose removal
2 Caliper removal
3 Master cylinder removal
Extent of removal Order Part name Q’ty Remarks
FRONT BRAKE REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake hose holder (protector) 2
2 Brake hose holder (caliper) 1
3 Union bolt 2
4 Brake hose 1
5 Pad pin plug 1 Remove when loosening the pad pin.
6 Pad pin 1 Loosen when disassembling the caliper.
7 Caliper 1
8Brake lever 1
9 Master cylinder bracket 1
10 Master cylinder
1
1
2
3
3
2

5 - 11
CHAS
EC5A8100
REAR BRAKE
Extent of removal:
1 Master cylinder removal
2 Brake hose removal
3 Caliper removal
Extent of removal Order Part name Q’ty Remarks
REAR BRAKE REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake pedal 1
2 Master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8 Caliper 1
1
123
3
FRONT BRAKE AND REAR BRAKE

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CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:
1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Headlight
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Pinch bolt (handle crown) 2 Only loosening.
3 Cap bolt 1 Loosen when disassembling the front fork.
4 Pinch bolt (under bracket) 2 Only loosening.
5 Front fork 1
1

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CHAS
EC5B0000
HANDLEBAR
Extent of removal:
1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
HANDLEBAR REMOVAL
Preparation for removal Headlight
1 Hot starter cable 1 Disconnect at the lever side.
2 Hot starter lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1 Disconnect the clutch switch lead.
5“ENGINE STOP” button 1 Disconnect the “ENGINE STOP” button
lead.
6 Master cylinder 1 Refer to “REMOVAL POINTS”.
7 Start switch 1 Disconnect the start switch lead.
8 Throttle cable cap 1
9 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
10 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
11 Grip (right) 1 Refer to “REMOVAL POINTS”.
12 Tube guide 1
13 Grip (left) 1 Refer to “REMOVAL POINTS”.
14 Handlebar holder (upper) 2
15 Handlebar 1
16 Handlebar holder (lower) 2
1
HANDLEBAR

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CHAS
LENKER
Arbeitsumfang:
1 Lenker demontieren
ArbeitsumfangReihen-
folgeBauteil Anz. Bemerkungen
LENKER DEMONTIEREN
Vorbereitungsarbeiten Scheinwerfer
1 Warmstartzug 1 Hebelseitig lösen.
2 Warmstarthebel-Halterung 1
3 Kupplungszug 1 Hebelseitig lösen.
4 Kupplungshebel-Halterung 1 Das Kupplungsschalter-Kabel lösen.
5 Motorstoppschalter “ENGINE STOP”1 Das Motorstoppschalter-Kabel lösen.
6 Hauptbremszylinder 1 Siehe unter “DEMONTAGE-EINZELHEITEN”.
7 Starterschalter 1 Das Starterschalter-Kabel lösen.
8 Gaszug-Abdeckung 1
9 Gasgeberzug 1 1 Gasdrehgriffseitig lösen.
10 Gasnehmerzug 2 1 Gasdrehgriffseitig lösen.
11 Lenkergriff rechts 1 Siehe unter “DEMONTAGE-EINZELHEITEN”.
12 Führung 1
13 Lenkergriff links 1 Siehe unter “DEMONTAGE-EINZELHEITEN”.
14 Lenker-Halterung (oben) 2
15 Lenker 1
16 Lenker-Halterung (unten) 2
1
GUIDON
Organisation de la dépose:1 Dépose du guidon
Organisation de la dépose Ordre Nom de la pièce QtéRemarques
DEPOSE DU GUIDON
Préparation à la dépose Phare
1Câble de démarrage à chaud 1 Déconnecter du côté levier.
2 Support du levier de démarrage à chaud 1
3Câble d’embrayage 1 Déconnecter du côté levier.
4 Support de levier d’embrayage 1 Déconnecter le fil du contacteur d’embrayage.
5 Bouton “ENGINE STOP”1Débrancher le fil du bouton “ENGINE STOP”.
6Maître-cylindre 1 Se reporter à “POINTS DE DEPOSE”.
7 Contacteur du démarreur 1 Déconnecter le fil du contacteur du démarreur.
8 Couvercle du logement de câble des gaz 1
9Câble des gaz n°1 (tiré)1Déconnecter du côté accélérateur.
10 Câble des gaz n°2 (enfoncé)1Déconnecter du côté accélérateur.
11 Poignée (droite) 1 Se reporter à “POINTS DE DEPOSE”.
12 Guide de tube 1
13 Poignée (gauche) 1 Se reporter à “POINTS DE DEPOSE”.
14 Support du guidon (supérieur) 2
15 Guidon 1
16 Support du guidon (inférieur) 2
1
MANILLAR
Extensión del desmontaje:1 Desmontaje del manillar
Extensión del desmontaje Orden Nombre de la pieza Ctd. Observaciones
DESMONTAJE DEL MANILLAR
Preparación para el desmontaje Faro
1 Cable de arranque en caliente 1 Desconéctelo del lado de la maneta.
2 Soporte del mando de arranque en caliente 1
3 Cable de embrague 1 Desconéctelo del lado de la maneta.
4 Soporte de la maneta de embrague 1 Desconecte el cable del interruptor del embrague.
5Botón “ENGINE STOP” (paro del motor) 1 Desconecte el cable del botón “ENGINE STOP”.
6 Bomba de freno 1 Consulte el apartado “PUNTOS DE DESMONTAJE”.
7 Interruptor de arranque 1 Desconecte el cable del interruptor de arranque.
8 Tapa del cable del acelerador 1
9 Cable del acelerador nº 1 (en tracción) 1 Desconéctelo del lado del acelerador.
10 Cable del acelerador nº 2 (empujado) 1 Desconéctelo del lado del acelerador.
11 Puño (derecho) 1 Consulte el apartado “PUNTOS DE DESMONTAJE”.
12 Guía de tubo 1
13 Puño( izquierdo) 1 Consulte el apartado “PUNTOS DE DESMONTAJE”.
14 Soporte del manillar (superior) 2
15 Manillar 1
16 Sporte del manillar (inferior) 2
1
GUIDON
LENKER
MANILLAR

5 - 44
CHASHANDLEBAR
10. Install:
•Start switch 1
•Master cylinder 2
•Master cylinder bracket 3
•Bolt (master cylinder bracket) 4
•Clamp 5
NOTE:
•The start switch and master cylinder bracket
should be installed according to the dimen-
sions shown.
•Install the bracket so that the arrow mark a
faces upward.
•First tighten the bolt on the upper side of the
master cylinder bracket, and then tighten the
bolt on the lower side.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
Zero mm
(Zero in)Zero mm
(Zero in)
11. Install:
•“ENGINE STOP” button 1
•Clutch lever holder 2
•Bolt (clutch lever holder) 3
•Hot starter lever holder 4
•Bolt (hot starter lever holder) 5
•Clamp 6
NOTE:
•The “ENGINE STOP” button, clutch lever
holder and clamp should be installed accord-
ing to the dimensions shown.
•Pass the “ENGINE STOP” button lead in the
middle of the clutch lever holder.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
12. Install:
•Clutch cable 1
•Hot starter cable 2
NOTE:
Apply the lithium soap base grease on the
clutch cable end and hot starter cable end.