relay YAMAHA WR 450F 2007 Owners Manual

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 10 1.0 7.2
Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
Engine upper bracket and frame M10 × 1.25 4 55 5.5 40
Engine lower bracket and frame M8 × 1.25 4 34 3.4 24
Engine and engine bracket (lower) M10 × 1.25 1 53 5.3 38
Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
Engine and frame (lower) M10 × 1.25 1 53 5.3 38
Engine guard M6 × 1.0 3 7 0.7 5.1
Regulator mounting M6 × 1.0 2 7 0.7 5.1
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
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 38 3.8 27
Rear frame and frame (lower) M8 × 1.25 2 32 3.2 23
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 16 1.6 11
Drive chain tensioner mounting (lower) M8 × 1.25 1 16 1.6 11
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 9 0.9 6.5
Fuel tank and fuel cock M6 × 1.0 2 4 0.4 2.9
Fuel tank and seat set bracket 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
Multi-function display mounting M5 × 0.8 2 4 0.4 2.9
Plate 1 and protector M5 × 0.8 2 4 0.4 2.9
Plate 2 and protector—2 0.5 0.05 0.36
MAINTENANCE SPECIFICATIONS

SPEC
2 - 19
NOTE:
Tighten the rotor nut to 65 Nm (6.5 m  kg, 47 ft  lb), loosen and retighten the rotor nut to 65 Nm
(6.5 m  kg, 47 ft  lb). Starter relay:
Model/manufacturer 2768090-A/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 °C (68 °F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221 M06/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 °C (68 °F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M5 × 0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5 × 0.8 2 10 1.0 7.2
Rotor M12 × 1.25 1 Refer to NOTE.
Neutral switch M5 × 0.8 2 4 0.4 2.9
Starter motor M6 × 1.0 2 10 1.0 7.2
Starter relay terminal M6 × 1.0 2 4 0.4 2.9
Pick-up coil M6 × 1.0 2 10 1.0 7.2 Item Standard Limit
MAINTENANCE SPECIFICATIONS

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.

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
* marked: For USA
FRONT FORKS
Inspect and adjust
Replace oil Suspension oil “S1”
Replace oil seal
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube Lithium base grease
PROTECTOR GUIDE
Replace
REAR SHOCK ABSORBER
(After
rain ride)
Inspect and adjust
Lube
Molybdenum disulfide
grease
Retighten
DRIVE CHAIN GUARD AND ROLL-
ERS
Inspect
SWINGARM
Molybdenum disulfide
grease
Inspect, lube and retighten
RELAY ARM, CONNECTING ROD
Molybdenum disulfide
grease
Inspect, lube and retighten
SIDESTAND
Lubricate Lithium base grease
STEERING HEAD
Inspect free play and retighten
Clean and lube Lithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate Lithium base grease
THROTTLE, CONTROL CABLE
Yamaha cable lube or
SAE 10W-30 motor oil Check routing and connection
Lubricate
HOT STARTER, CLUTCH LEVER
Inspect free play
BATTERY
Check terminal for looseness and
corrosionItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks

5 - 52
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:
1 Swingarm
removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM 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.
Brake hose holder
Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Rear caliper
Bolt (brake pedal) Shift the brake pedal backward.
Drive chain
1 Chain support 1
2 Chain tensioner (lower) 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1

5 - 53
CHASSWINGARM
EC578000
SWINGARM DISASSEMBLY
Extent of removal:
1 Swingarm disassembly
2 Connecting rod removal and disassembly
3 Relay arm removal and disassembly
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1 Cap 2 Refer to “REMOVAL POINTS”.
2 Relay arm 1
3 Connecting rod 1
4 Collar 2
5 Oil seal 2
6 Thrust bearing 2
7 Bush 2
8 Oil seal 8
9 Bearing 10 Refer to “REMOVAL POINTS”.
1
2
32
3

5 - 54
CHASSWINGARM
EC573000
REMOVAL POINTS
Cap
1. Remove:
•Cap (left) 1
NOTE:
Remove with a slotted-head screwdriver
inserted under the mark a on the cap (left).
EC573200
Bearing
1. Remove:
•Bearing 1
NOTE:
Remove the bearing by pressing its outer race.
EC574010
INSPECTION
Wash the bearings, bushes and collars in a
solvent.
EC574111
Swingarm
1. Inspect:
•Bearing 1
•Bush 2
Free play exists/unsmooth revolution/rust
→ Replace bearing and bush as a set.
2. Inspect:
•Oil seal 3
Damage → Replace.
Relay arm
1. Inspect:
•Bearing 1
•Collar 2
Free play exists/unsmooth revolution/rust
→ Replace bearing and collar as a set.
2. Inspect:
•Oil seal 3
Damage → Replace.

5 - 55
CHASSWINGARM
Connecting rod
1. Inspect:
•Bearing 1
•Collar 2
Free play exists/unsmooth revolution/rust
→ Replace bearing and collar as a set.
2. Inspect:
•Oil seal 3
Damage → Replace.
EC575000
ASSEMBLY AND INSTALLATION
Bearing and oil seal
1. Install:
•Bearing 1
•Oil seal 2
To swingarm.
NOTE:
•Apply the molybdenum disulfide grease on
the bearing when installing.
•Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
•First install the outer and then the inner bear-
ings to a specified depth from inside.
Installed depth of bearings:
Outer
a: Zero mm (Zero in)
Inner
b: 6.5 mm (0.26 in)
2. Install:
•Bearing 1
•Plain washer 2
•Oil seal 3
To relay arm.
NOTE:
•Apply the molybdenum disulfide grease on
the bearing when installing.
•Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
•Apply the molybdenum disulfide grease on
the plain washer.
Installed depth of bearings
a:
Zero mm (Zero in)

5 - 56
CHASSWINGARM
3. Install:
•Bearing 1
•Oil seal 2
To connecting rod.
NOTE:
•Apply the molybdenum disulfide grease on
the bearing when installing.
•Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of bearings
a:
Zero mm (Zero in)
Swingarm
1. Install:
•Bush 1
•Thrust bearing 2
•Oil seal 3
•Collar 4
To swingarm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bushes, thrust bearings, oil seal lips and con-
tact surfaces of the collar and thrust bearing.
2. Install:
•Collar 1
•Washer 2
To relay arm 3.
NOTE:
Apply the molybdenum disulfide grease on the
collars and oil seal lips.