YAMAHA WR 450F 2009 Owners Manual

7-8
ELECTRIC STARTING SYSTEM
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
CHECKING THE STARTER
MOTOR OPERATION
1. Connect the positive battery ter-
minal "1" and starter motor lead
"2" with a jumper lead "3".
Not operate→Repair or replace
the starter motor.
• A wire that is used as a jumper
lead must have at least the same
capacity or more as that of the
battery lead, otherwise the jump-
er lead may burn.
• This check is likely to produce
sparks, therefore make sure
nothing flammable is in the vicin-
ity.
CHECKING THE STARTING
CIRCUIT CUT-OFF RELAY
1. Remove:
• Starting circuit cut-off relay
2. Inspect:
• Starting circuit cut-off relay con-
duction
Use 12 V battery.
Not conductive while the battery is
connected→Replace.
Conductive while the battery is not
connected→Replace.
Set the tester selection position to "Ω
× 1".
CHECKING THE STARTER RELAY
1. Remove:
• Starter relay
2. Inspect:
• Starter relay conduction
Use 12 V battery.
Not conductive while the battery is
connected→Replace.
Conductive while the battery is not
connected →Replace.
Set the tester selection position to "Ω
× 1".
CHECKING THE CLUTCH SWITCH
1. Inspect:
• Clutch switch conduction
Not conductive while it is pulled→Re-
place.
Conductive while it is freed→Re-
place.
Set the tester selection position to "Ω
× 1".
CHECKING THE DIODE
1. Remove the diode from wire har-
ness.
2. Inspect:
• Diode continuity
Use pocket tester (tester selec-
tion position Ω × 1)
Incorrect continuity→Replace. Battery (+) lead→Blue/Black lead
"1"
Battery (-) lead→Brown lead "2"
Tester (+) lead→Blue/White lead
"3"
Tester (-) lead→Black lead "4"
Result
Conductive (while the
battery is connected)
Battery (+) lead→Starter relay ter-
minal "1"
Battery (-) lead→Starter relay ter-
minal "2"
Tester (+) lead→Starter relay ter-
minal "3"
Tester (-) lead→Starter relay ter-
minal "4"
Result
Conductive (while the
battery is connected)
Tester (+) lead→Black lead "1"
Tester (-) lead→Black lead "2"
Result
Conductive (while the
clutch lever is pulled)
Tester (+)→Blue/Red
terminal "1"
Tester (-) →Sky blue
terminal "2"Continu-
ous
Tester (+)→Blue/Red
terminal "1"
Tester (-)→Blue/Yel-
low terminal "3"Continu-
ous
Tester (+)→Sky blue
terminal "2"
Tester (-)→Blue/Red
terminal "1"No con-
tinuous
Tester (+)→Blue/Yel-
low terminal "3"
Tester (-)→Blue/Red
terminal "1"No con-
tinuous

7-9
ELECTRIC STARTING SYSTEM
CHECKING THE START SWITCH
1. Inspect:
• Start switch conduction
Not conductive while it is pushed→
Replace.
Conductive while it is freed→Re-
place.
Set the tester selection position to "Ω
× 1".
2. Inspect:
• Rubber part "a"
Tears/damage→Replace. Tester (+) lead→Black lead "1"
Tester (-) lead→Black lead "2"
Result
Conductive (while the
start switch is pushed)

7-10
ELECTRIC STARTING SYSTEM
REMOVING THE STARTER MOTOR
Order Part name Q'ty Remarks
Exhaust pipeRefer to "REMOVING THE EXHAUST PIPE
AND SILENCER" section in the CHAPTER 3.
1 Starter motor 1

7-11
ELECTRIC STARTING SYSTEM
DISASSEMBLING THE STARTER MOTOR
Order Part name Q'ty Remarks
1 Starter motor front cover 1
2 Washer (starter motor front cover) 1
3 Washer 1
4 Circlip 1
5O-ring 1
6 Starter motor yoke 1
7 Armature assembly 1
8 Starter motor rear cover 1
9 Brush 2
10 Brush spring 2

7-12
ELECTRIC STARTING SYSTEM
CHECKING AND REPAIRING THE
STARTER MOTOR
1. Check:
• Commutator
Dirt→Clean with 600 grit sandpa-
per.
2. Measure:
• Commutator diameter "a"
Out of specification→Replace the
starter motor.
3. Measure:
• Mica undercut "a"
Out of specification→Scrape the
mica to the proper measurement
with a hacksaw blade which has
been grounded to fit the commu-
tator.
The mica must be undercut to ensure
proper operation of the commutator.
4. Measure:
• Armature assembly resistances
(commutator and insulation)
Out of specification→Replace the
starter motor.
a. Measure the armature assembly
resistances with the pocket tester.b. If any resistance is out of specifi-
cation, replace the starter motor.
5. Measure:
• Brush length "a"
Out of specification→Replace the
brushes as a set.
6. Measure:
• Brush spring force
Out of specification→Replace the
brush springs as a set.ASSEMBLING THE STARTER
MOTOR
1. Install:
• Brush spring "1"
• Brush "2"
2. Install:
• Armature assembly "1"
Install while holding down the
brush using a thin screw driver.
Be careful not to damage the brush
during installation.
3. Install:
• O-ring "1"
• Starter motor yoke "2"
• Align the match mark "a" on the
starter motor yoke with the match
mark "b" on the starter motor rear
cover.
• Install the starter motor yoke with its
groove "c" facing rear cover.
Min. commutator diame-
ter:
16.6 mm (0.65 in)
Mica undercut:
1.5 mm (0.06 in)
Pocket tester:
YU-3112-C/90890-
03112
Armature assembly:
Commutator resis-
tance "1":
0.0117–0.0143 Ω at 20
°C (68 °F)
Insulation resistance
"2":
Above 1 MΩat 20 °C
(68 °F)
Min. brush length:
3.5 mm (0.14 in)
Brush spring force:
3.92–5.88 N (400–600
gf, 14.1–21.2 oz)

7-13
ELECTRIC STARTING SYSTEM
4. Install:
• O-ring "1"
• Circlip
• Plain washer "2"
• Washer (starter motor front cover)
"3"
• Starter motor front cover "4"
• For installation, align the projec-
tions on the washer with the slots in
the front cover.
• Align the match mark "a" on the
starter motor yoke with the match
mark "b" on the starter motor front
cover.
5. Install:
•Bolt "1"
• O-ring "2"
Apply the lithium soap base grease
on the O-ring.

7-14
CHARGING SYSTEM
CHARGING SYSTEM
INSPECTION STEPS
If the battery is not charged, use the following inspection steps.
*1 marked: Refer to "CHECKING THE FUSE" section in the CHAPTER 3.
*2 marked: Refer to "CHECKING AND CHARGING THE BATTERY" section in the CHAPTER 3.
• Remove the following parts before inspection.
1. Seat
2. Fuel tank
• Use the following special tools in this inspection.
*1 Check fuse. No good→Replace fuse and check wire harness.
OK↓
*2 Check battery. No good→Recharge or replace.
OK↓
Check each coupler and wire connection. No good→Repair or replace.
OK↓
Check charging voltage. OK→Charging system is good.
No good↓
Check AC magneto. (Charging coil) No good→Replace.
OK↓
Replace rectifier/regulator.
Pocket tester:
YU-3112-C/90890-03112

7-15
CHARGING SYSTEM
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
CHECKING THE CHARGING
VOLTAGE
1. Start the engine.
2. Inspect:
• Charging voltage
Out of specification→If no failure
is found in checking the source
coil resistance, replace the rectifi-
er/regulator.
3. Inspect:
• Charging coil resistance
Out of specification→Replace. Tester (+) lead→Red lead "1"
Tester (-) lead→Black lead "2"
Charging
voltageTester se-
lector posi-
tion
14.0–15.0 V
at 5,000 r/
minDCV-20
Tester (+) lead→White lead "1"
Tester (-) lead→Ground "2"
Charging
coil resis-
tanceTester se-
lector posi-
tion
0.288–0.432
Ω at 20 °C
(68 °F)Ω × 1

7-16
THROTTLE POSITION SENSOR SYSTEM
THROTTLE POSITION SENSOR SYSTEM
INSPECTION STEPS
If the throttle position sensor will not operate, use the following inspection steps.
Use the following special tools in this inspection.
Check entire ignition system for connection. No good→Repair or replace.
OK↓
Check throttle position sensor.(Throttle position
sensor coil)No good→
Replace.
OK↓
Check CDI unit.(Throttle position sensor input
voltage)No good→
Replace.
Pocket tester:
YU-3112-C/90890-03112

7-17
THROTTLE POSITION SENSOR SYSTEM
HANDLING NOTE
Do not loosen the screw (throttle
position sensor) "1" except when
changing the throttle position sen-
sor due to failure because it will
cause a drop in engine perfor-
mance.
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
CHECKING THE THROTTLE
POSITION SENSOR COIL
1. Inspect:
• Throttle position sensor coil resis-
tance
Out of specification→Replace.
2. Loosen:
• Throttle stop screw "1"
Turn out the throttle stop screw until
the throttle shaft is in the full close po-
sition.
3. Inspect:
• Throttle position sensor coil vari-
able resistance
Check that the resistance in in-
creased as the throttle grip is
moved from the full close position
to the full open position.
Out of specification→Replace.
CHANGING AND ADJUSTING THE
THROTTLE POSITION SENSOR
1. Remove:
• Throttle position sensor coupler
• Carburetor
2. Remove:
• Screw (throttle position sensor)
"1"
• Throttle position sensor "2"
Loosen the screw (throttle position
sensor) using the T25 bit.
3. Replace:
• Throttle position sensor4. Install:
• Throttle position sensor "1"
• Screw (throttle position sensor)
"2"
• Align the slot "a" in the throttle posi-
tion sensor with the projection "b"
on the carburetor.
• Temporarily tighten the screw
(throttle position sensor).
5. Install:
•Carburetor
• Throttle position sensor coupler
6. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section in
the CHAPTER 3.
7. Insert the thin electric conductors
"2" (lead) into the throttle position
sensor coupler "1", as shown, and
connect the tester to them.
• Do not insert the electric conduc-
tors more than required because
it may reduce the waterproof
function of the coupler.
• Make sure that a short-circuit
does not develop between the
terminals because it may cause
damage to electrical compo-
nents.
8. Start the engine. Tester (+) lead→Blue lead "1"
Tester (-) lead→Black lead "2"
Throttle po-
sition sen-
sor coil
resistanceTester se-
lector posi-
tion
4–6 kΩ at
20°C (68 °F) kΩ×1
Tester (+) lead→Yellow lead "1"
Tester (-) lead→Black lead "2"
Throttle position
sensor coil vari-
able resistanceTester
selec-
tor po-
sition
Full
closedFull
opened
kΩ×1 Zero –2
kΩat
20°C
(68 °F)4–6
kΩat
20 °C
(68 °F)
Tester (+) lead→Yellow lead "3"
Tester (-) lead→Black lead "4"