light YAMAHA WR 450F 2007 User Guide

SPEC
2 - 17
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Speed sensor lead holder and under bracket M6 × 1.0 1 13 1.3 9.4
Headlight body and headlight unit—210.10.7
Headlight mounting (left and right) M6 × 1.0 2 7 0.7 5.1
Taillight mounting—310.10.7
Taillight lead clamp and rear fender—3 0.5 0.05 0.36
Catch tank (upper) M6 × 1.0 1 16 1.6 11
Catch tank (lower) M6 × 1.0 1 7 0.7 5.1
Footrest bracket and frame M10 × 1.25 4 55 5.5 40
Sidestand mounting M10 × 1.25 1 25 2.5 18 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
MAINTENANCE SPECIFICATIONS

SPEC
2 - 18
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
C.D.I.:
Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)
(White – Red)----
CDI unit-model/manufacturer 5TJ-E0/YAMAHA (For USA)
5TJ-F0/YAMAHA
(Except for USA)----
----
Ignition coil:
Model/manufacturer 5TA-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ----
Secondary winding resistance 4.6 ~ 6.8 kΩ at 20 °C (68 °F) ----
Charging system:
System type AC magneto ----
Model (stator)/manufacturer 5TJ 40/YAMAHA ----
Normal output 14 V/120 W at 5,000 r/min ----
Charging coil resistance (color) 0.288 ~ 0.432 Ω at 20 °C (68 °F)
(White – Ground)----
Lighting coil resistance (color) 0.224 ~ 0.336 Ω at 20 °C (68 °F)
(Yellow – Ground)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH770AA/SHINDENGEN ----
Regulated voltage (AC) 12.5 ~ 13.5 V ----
Regulated voltage (DC) 14.0 ~ 15.0 V ----
Rectifier capacity (AC) 12 A ----
Rectifier capacity (DC) 8 A ----
Electric starting system:
Type Constant mesh ----
Starter motor:
Model/manufacturer 5UM20/YAMAHA ----
Operation voltage 12 V ----
Output 0.48 kW ----
Armature coil resistance 0.0117 ~ 0.0143 Ω at 20 °C
(68 °F)----
Brush overall length 7 mm (0.28 in) 3.5 mm
(0.14 in)
Brash quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm
(0.65 in)
Mica undercut (depth) 1.5 mm (0.06 in) ----
MAINTENANCE SPECIFICATIONS

2 - 25
SPECCABLE ROUTING DIAGRAM
ÐFasten the AC magneto lead and neutral switch
lead onto the frame. Locate the clamp end fac-
ing toward the rear of the frame and cut off the
tie end.
ÑPass the neutral switch lead and AC magneto
lead on the inside of the wire harness.
ÒFasten the AC magneto lead and neutral switch
lead onto the frame.
ÓPass the wire harness through the cable guide.
ÔLocate the couplers in the frame recess.
ÕPass the carburetor breather hoses, carburetor
overflow hose and catch tank breather hose so
that the hoses do not contact the rear shock
absorber.
ÖSecure the coupler by pushing it into the hole inthe headlight unit.

2 - 27
SPECCABLE ROUTING DIAGRAM
1Brake master cylinder
2Brake hose holder
3Brake hoseÈInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projec-
tion on the brake caliper.
ÉPass the brake hose into the brake hose hold-
ers.
ÊIf the brake hose contacts the spring (rear shock
absorber), correct its twist.
ËInstall the brake hose so that its pipe portion
directs as shown and lightly touches the projec-
tion on the brake master cylinder.

2 - 28
SPECCABLE ROUTING DIAGRAM
1Clamp
2Positive battery lead
3Battery
4Negative battery lead
5Taillight coupler
6CDI unit coupler (6-pin)
7CDI unit coupler (3-pin)
8CDI unit coupler (6-pin)ÈFasten the wire harness to the upper engine
bracket (left side). Locate the clamp end facing
toward the upper side of the frame with the tie
end cut off on the inside of the frame.
ÉFasten the wire harness to the upper engine
bracket (left side). Locate the clamp end facing
toward the upper side of the frame with the tie
end cut off on the inside of the frame. Clamp the
wire harness at the marking.
ÊPass the starter motor lead through the hole in
the relay holder.
ËFit the cover securely.
ÌConnect the wire harness to the starter relay.

2 - 29
SPECCABLE ROUTING DIAGRAM
ÍFasten the catch tank breather
hose and catch tank hose to the
rear frame. Clamp them close
to where they are joined to the
frame. Fasten the pipe tightly
enough not to crush it. Locate
the clamp end facing toward the
rear of the frame with the tie
end facing downward.
ÎFasten the (three) CDI unit
leads and taillight lead to the
rear frame. Locate the clamp
end facing toward the upper
side of the frame and cut off the
tie end.
ÏConnect the negative battery
lead to the battery negative ter-
minal.
ÐConnect the negative battery
lead to the wire harness.ÑFasten the wire harness to the
rear frame. Locate the clamp
end facing toward the upper
side of the frame and the tie
end toward the inside of the
frame. Clamp the wire harness
at the marking.
ÒPass the wire harness, starter
relay lead, starting circuit cut-off
relay lead and negative battery
lead through the hole in the
relay holder.
ÓFasten the (three) CDI unit
leads and taillight lead to the
rear frame. Locate the clamp
end facing toward the lower
side of the frame and cut off the
tie end.ÔFasten the taillight lead to the
rear frame. Locate the clamp
end facing toward the upper
side of the frame and cut off the
tie end.
ÕDo not allow the taillight lead to
slacken.
ÖLocate the CDI unit lead
between the CDI unit and rear
fender.
×Locate the CDI unit coupler in
the clearance between the
upper side of the CDI unit and
lower side of the catch tank
stay.
ØLocate the CDI unit lead
between the CDI unit and rear
frame.

2 - 30
SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Clamp
3Brake hose
4Clutch cable
5Hose guide
6Main switch coupler
7Wire harness
8Headlight coupler
9Hot starter cable
0Multi-function display bracket
AMain switch
BUpper bracket
CClutch switch coupler
DEngine stop switch coupler
EMulti-function display coupler
FStart switch coupler
GSpeed sensor coupler
HSpeed sensor lead

3 - 14
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
ENGINE OIL LEVEL INSPECTION
1. Stand the machine on a level surface.
NOTE:
When checking the oil level make sure that
the machine is upright.
Place the machine on a suitable stand.
WARNING
Never remove the oil tank cap just after
high speed operation. The heated oil could
spurt out. causing danger. Wait until the oil
cools down to approximately 70 °C (158 °F).
2. Idle the engine more than 3 minutes while
keeping the machine upright. Then stop the
engine and inspect the oil level.
3. Remove:
Oil tank plug 1
4. Inspect:
Oil level
Check that the engine oil is above the
level mark a and that the oil does not
come out when the check bolt 1 is
removed.
Below the level mark a → Add oil
through the filler cap hole until it is above
the level mark a.
Oil comes out at the check bolt → Drain
the oil until it stops coming out.
NOTE:
When inspecting the oil level, do not screw the
oil level gauge into the oil tank.
Insert the gauge lightly.

3 - 18
INSP
ADJ
IDLE SPEED ADJUSTMENT
9. Check:
Oil pressure
Checking steps:
Slightly loosen the oil gallery bolt 1.
Start the engine and keep it idling until oil
starts to seep from the oil gallery bolt. If no
oil comes out after one minute, turn the
engine off so it will not seize.
Check oil passages, oil filter and oil pump
for damage or leakage.
Start the engine after solving the prob-
lem(s) and recheck the oil pressure.
Tighten the oil gallery bolt to specification.
T R..
Oil gallery bolt:
10 Nm (1.0 m  kg, 7.2 ft  lb)
EC35M021
IDLE SPEED ADJUSTMENT
1. Start the engine and thoroughly warm it up.
2. Adjust:
Idle speed
Adjustment steps:
Turn the throttle stop screw 1 until the
specified engine idling speed.
NOTE:
Using a digital engine tachometer for idle
speed adjustment, detect the engine idling
speed by bringing the sensing element c of
the engine tachometer close to the ignition
coil 2.
To increase idle speed
→
Turn the throttle stop screw
1 in
a.
To decrease idle speed
→
Turn the throttle stop screw
1 out
b.
Engine idling speed:
1,750 ~ 1,850 r/min
c2

3 - 24
INSP
ADJ
SPARK ARRESTER CLEANING (For USA)
WARNING
Be sure the exhaust pipe and silencer are
cool before cleaning the spark arrester.
Do not start the engine when cleaning the
exhaust system.
1. Remove:
Screw (silencer cap) 1
1
2. Remove:
Bolt (spark arrester) 1
1
3. Remove:
Tail pipe 1
Gasket (tail pipe) 2
Spark arrester 3
Pull the spark arrester out of the silencer.
Gasket (spark arrester) 4
4. Clean:
Spark arrester
Tap the spark arrester lightly, then use a
wire brush to remove any carbon depos-
its.
5. Install:
Gasket (spark arrester)
Spark arrester
Insert the spark arrester into the silencer
and align the bolt holes.
Gasket (tail pipe)
Bolt (spark arrester)
12
34
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
6. Install:
Silencer cap
NOTE:
First tighten the two screws a located horizon-
tally apart, and then tighten the others.aa
T R..5 Nm (0.5 m · kg, 3.6 ft · lb)
SPARK ARRESTER CLEANING (For USA)