ad blue YAMAHA WR 450F 2009 Owners Manual

4-7
CHASSIS
CHOOSING SET LENGTH
1. Place a stand or block under the
engine to put the rear wheel
above the floor, and measure the
length "a" between the rear wheel
axle center and the rear fender
holding bolt.
2. Remove the stand or block from
the engine and with a rider astride
the seat, measure the sunken
length "b" between the rear wheel
axle center and the rear fender
holding bolt.
3. Loosen the locknut "1" and make
adjustment by turning the spring
adjuster "2" to achieve the stan-
dard figure from the subtraction of
the length "b" from the length "a".
• If the machine is new and after it is
broken in, the same set length of
the spring may change because of
the initial fatigue, etc. of the spring.
Therefore, be sure to make reeval-
uation.
• If the standard figure cannot be
achieved by adjusting the spring
adjuster and changing the spring
set length, replace the spring with
an optional one and make re-ad-
justment.
SETTING OF SPRING AFTER
REPLACEMENT
After replacement, be sure to adjust
the spring to the set length [sunken
length 90–100 mm (3.5–3.9 in)] and
set it.
1. Use of soft spring
• Set the soft spring for less re-
bound damping to compensate
for its less spring load. Run with
the rebound damping adjuster
one or two clicks on the softer
side and readjust it to suit your
preference.
2. Use of stiff spring
• Set the soft spring for more re-
bound damping to compensate
for its greater spring load. Run
with the rebound damping adjust-
er one or two clicks on the stiffer
side and readjust it to suit your
preference.
Adjusting the rebound damping will
be followed more or less by a change
in the compression damping. For cor-
rection, turn the low compression
damping adjuster on the softer side.
When using a rear shock absorber
other than currently installed, use
the one whose overall length "a"
does not exceed the standard as it
may result in faulty performance.
Never use one whose overall
length is greater than standard.
REAR SHOCK ABSORBER
SETTING PARTS
• Rear shock spring "1"
• The I.D. mark "a" is marked at the
end of the spring.
• Spring specification varies accord-
ing to the color and quantity of I.D.
marks.
• Extent of adjustment (spring pre-
load)
For the spring preload adjustment, re-
fer to "ADJUSTING THE REAR
SHOCK ABSORBER SPRING PRE-
LOAD" in the CHAPTER 3.
Standard figure:
90–100 mm (3.5–3.9 in)
Length "a" of standard
shock:
488.5 mm (19.23 in)
TYPESPRI
NG
RAT
ESPRING
PART
NUM-
BER
(-22212-)I.D.
MARK/
Q'TY
SOFT 4.3 5UN-00 Brown/1
4.5 5UN-10 Green/1
4.7 5UN-20 Red/1
4.9 5UN-30 Black/1
5.1 5UN-40 Blue/1
5.3 5UN-50 Yellow/1
STD 5.5 5UN-60 Pink/1
STIFF5.7 5UN-70 White/1
Maximum Minimum
Position in
which the
spring is turned
in 13 mm (0.51
in) from its free
length.Position in
which the
spring is turned
in 1.5 mm (0.06
in) from its free
length.

5-17
CAMSHAFTS
REMOVING THE CAMSHAFT
1. Remove:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw
"2"
2. Align:
• T.D.C. mark
With align mark.
Checking steps:
a. Turn the crankshaft counterclock-
wise with a wrench.
b. Align the T.D.C. mark "a" on the
rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
In order to be sure that the piston is at
Top Dead Center, the punch mark "c"
on the exhaust camshaft and the
punch mark "d" on the intake cam-
shaft must align with the cylinder
head surface, as shown in the illustra-
tion.
3. Remove:
• Timing chain tensioner cap bolt
"1"
• Timing chain tensioner "2"
• Gasket
4. Remove:
• Bolt (camshaft cap) "1"
• Camshaft cap "2"
• Clip
Remove the bolts (camshaft cap) in a
crisscross pattern, working from the
outside in.
The bolts (camshaft cap) must be
removed evenly to prevent dam-
age to the cylinder head, cam-
shafts or camshaft caps.
5. Remove:
• Exhaust camshaft "1"
• Intake camshaft "2"
Attach a wire "3" to the timing chain to
prevent it from falling into the crank-
case.
CHECKING THE CAMSHAFT
1. Inspect:
•Cam lobe
Pitting/scratches/blue discolora-
tion→Replace.
2. Measure:
• Cam lobe length "a" and "b"
Out of specification→Replace.
Cam lobes length:
Intake "a":
30.100–30.200 mm
(1.1850–1.1890 in)
:
30.000 mm (1.1811 in)
Intake "b":
22.450–22.550 mm
(0.8839–0.8878 in)
:
22.350 mm (0.8799 in)
Exhaust "a":
30.200–30.300 mm
(1.1890–1.1929 in)
:
30.100 mm (1.1850 in)
Exhaust "b":
22.450–22.550 mm
(0.8839–0.8878 in)
:
22.350 mm (0.8799 in)

5-25
VALVES AND VALVE SPRINGS
3. Inspect:
• Valve face
Pitting/wear→Grind the face.
• Valve stem end
Mushroom shape or diameter
larger than the body of the stem→
Replace.
4. Measure:
• Margin thickness "a"
Out of specification→Replace.
5. Measure:
• Runout (valve stem)
Out of specification→Replace.
• When installing a new valve always
replace the guide.
• If the valve is removed or replaced
always replace the oil seal.
6. Eliminate:
• Carbon deposits
(from the valve face and valve
seat)
7. Inspect:
• Valve seat
Pitting/wear→Reface the valve
seat.
8. Measure:
• Valve seat width "a"
Out of specification→Reface the
valve seat.
Measurement steps:
a. Apply Mechanic's blueing dye
(Dykem) "b" to the valve face.
b. Install the valve into the cylinder
head.
c. Press the valve through the valve
guide and onto the valve seat to
make a clear pattern.
d. Measure the valve seat width.
Where the valve seat and valve
face made contact, blueing will
have been removed.
e. If the valve seat is too wide, too
narrow, or the seat is not cen-
tered, the valve seat must be re-
faced.
9. Lap:
• Valve face
• Valve seat
After refacing the valve seat or re-
placing the valve and valve guide, the
valve seat and valve face should be
lapped.
Lapping steps:
a. Apply a coarse lapping compound
to the valve face.
Do not let the compound enter the
gap between the valve stem and
the guide.
b. Apply molybdenum disulfide oil to
the valve stem.
c. Install the valve into the cylinder
head.
d. Turn the valve until the valve face
and valve seat are evenly pol-
ished, then clean off all of the
compound.
For best lapping results, lightly tap
the valve seat while rotating the valve
back and forth between your hands.
e. Apply a fine lapping compound to
the valve face and repeat the
above steps.
After every lapping operation be sure
to clean off all of the compound from
the valve face and valve seat.
f. Apply Mechanic's blueing dye
(Dykem) to the valve face.
g. Install the valve into the cylinder
head.
h. Press the valve through the valve
guide and onto the valve seat to
make a clear pattern.
i. Measure the valve seat width
again. If the valve seat width is out
of specification, reface and relap
the valve seat.
Margin thickness:
Intake:
1.0 mm (0.039 in)
:0.85 mm
(0.033 in)
Exhaust:
1.0 mm (0.039 in)
:0.85 mm
(0.033 in)
Runout limit:
0.01 mm (0.0004 in)
Valve seat width:
Intake:
0.9–1.1 mm (0.0354–
0.0433 in)
:1.6 mm
(0.0630 in)
Exhaust:
0.9–1.1 mm (0.0354–
0.0433 in)
:1.6 mm
(0.0630 in)

5-26
VALVES AND VALVE SPRINGS
CHECKING THE VALVE SPRINGS
1. Measure:
• Valve spring free length "a"
Out of specification→Replace.
2. Measure:
• Compressed spring force "a"
Out of specification→Replace.
b. Installed length
3. Measure:
• Spring tilt "a"
Out of specification→Replace.CHECKING THE VALVE LIFTERS
1. Inspect:
• Valve lifter
Scratches/damage→Replace
both lifters and cylinder head.
INSTALLING THE VALVES
1. Apply:
• Molybdenum disulfide oil
Onto the valve stem and valve
stem seal.
2. Install:
• Valves "1"
• Valve spring seats "2"
• Valve stem seals "3"
• Valve springs "4"
• Valve spring retainers "5"
• Make sure that each valve is in-
stalled in its original place, also re-
ferring to the painted color as
follows.
Intake (middle) "a": blue
Intake (right/left) "b": gray
Exhaust "c": brown
• Install the valve springs with the
larger pitch "d" facing upward.
e. Smaller pitch3. Install:
• Valve cotters
While compressing the valve spring
with a valve spring compressor "1" in-
stall the valve cotters.
4. To secure the valve cotters onto
the valve stem, lightly tap the
valve tip with a piece of wood.
Hitting the valve tip with excessive
force could damage the valve.
5. Install:
• Adjusting pad "1"
• Valve lifter "2"
• Apply the molybdenum disulfide oil
on the valve stem end.
• Apply the engine oil on the valve lift-
ers.
• Valve lifter must turn smoothly
when rotated with a finger.
• Be careful to reinstall valve lifters
and pads in their original place.
Free length (valve
spring):
Intake:
39.46 mm (1.55 in)
: 38.46 mm
(1.51 in)
Exhaust:
37.61 mm (1.48 in)
: 36.61 mm
(1.44 in)
Compressed spring
force:
Intake:
130.2–149.8 N at 27.87
mm (13.28–15.28 kg at
27.87 mm, 29.27–
33.68 lb at 1.10 in)
Exhaust:
123.1–141.7 N at 28.38
mm (12.55–14.45 kg at
28.38 mm, 27.67–
31.85 lb at 1.12 in)
Spring tilt limit:
Intake:
2.5°/1.7 mm (0.067 in)
Exhaust:
2.5°/1.6 mm (0.063 in)
Valve spring compres-
sor:
YM-4019/90890-04019

5-29
CYLINDER AND PISTON
You cannot measure the end gap on
the expander spacer of the oil control
ring. If the oil control ring rails show
excessive gap, replace all three rings.
CHECKING THE PISTON PIN
1. Inspect:
• Piston pin
Blue discoloration/grooves→Re-
place, then inspect the lubrication
system.
2. Measure:
• Piston pin-to-piston clearance
Measurement steps:
a. Measure the outside diameter
(piston pin) "a".
If out of specification, replace the
piston pin.
b. Measure the inside diameter (pis-
ton) "b".
c. Calculate the piston pin-to-piston
clearance with the following for-mula.
d. If out of specification, replace the
piston.
INSTALLING THE PISTON RING
AND PISTON
1. Install:
•Piston ring
Onto the piston.
• Be sure to install the piston rings so
that the manufacturer's marks or
numbers are located on the upper
side of the rings.
• Lubricate the piston and piston
rings liberally with engine oil.
2. Position:
•Top ring
• 2nd ring
• Oil ring
Offset the piston ring end gaps as
shown.
a. Top ring end
b. 2nd ring end
c. Oil ring end (upper)
d. Oil ring
e. Oil ring end (lower)
3. Install:
•Piston "1"
• Piston pin "2"
• Piston pin clip "3"
• Apply engine oil onto the piston pin and piston.
• Be sure that the arrow mark "a" on
the piston points to the exhaust side
of the engine.
• Before installing the piston pin clip,
cover the crankcase with a clean
rag to prevent the piston pin clip
from falling into the crankcase.
• Install the piston pin clips with their
ends facing downward.
INSTALLING THE CYLINDER
1. Install:
• Dowel pins
• Cylinder gasket "1"
• Cylinder "2"
Install the cylinder with one hand
while compressing the piston rings
with the other hand.
• Pass the timing chain "3"
through the timing chain cavity.
• Be careful not to damage the tim-
ing chain guide "4" during instal-
lation.
2. Install:
• Bolt (cylinder) End gap:
Standard
Top
ring0.20–0.30
mm (0.008–
0.012 in)0.55 mm
(0.022 in)
2nd
ring0.35–0.50
mm (0.014–
0.020 in)0.85 mm
(0.033 in)
Oil
ring0.20–0.50
mm (0.01–
0.02 in)—
Outside diameter (piston
pin):
17.991–18.000 mm
(0.7083–0.7087 in)
Inside diameter (piston):
18.004–18.015 mm
(0.7088–0.7093 in)
Piston pin-to-piston clearance =
Inside diameter (piston) "b" -
Outside diameter (piston pin)
"a"
Piston pin-to-piston
clearance:
0.004–0.024 mm
(0.00016–0.00094 in)
:0.07 mm (0.003
in)
Bolt (cylinder):
10 Nm (1.0 m•kg, 7.2
ft•lb)
New

7-3
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
WIRING DIAGRAM
1. Headlight
2. Multi-function display
3. Engine stop switch
4. Clutch switch
5. Diode
6. Starter relay diode
7. Throttle position sensor
8. Starter relay
9. Fuse
10. Starting circuit cut-off relay
11. CDI unit
12. Taillight
13. Neutral switch
14. Starter motor
15. AC magneto
16. Rectifier/regulator
17. Ignition coil
18. Spark plug
19. Start switch
20. Main switch
21. Speed sensor
22. Battery
*1: For USA, CDN and EUROPE
*2: For AUS, NZ and ZACOLOR CODE
BBlack
Br Brown
Ch Chocolate
Dg Dark green
GGreen
Gy Gray
LBlue
O Orange
RRed
Sb Sky blue
WWhite
YYellow
B/L Black/Blue
B/W Black/White
L/B Blue/Black
L/R Blue/Red
L/Y Blue/Yellow
L/W Blue/White
R/B Red/Black
R/W Red/White

7-6
ELECTRIC STARTING SYSTEM
3. Inspect:
• Secondary coil resistance
Out of specification→Replace.
4. Inspect:
• Sealed portion of ignition coil "a"
• Spark plug terminal pin "b"
• Threaded portion of spark plug "c"
Wear →Replace.
CHECKING THE AC MAGNETO
1. Inspect:
• Pickup coil resistance
Out of specification→Replace.CHECKING THE NEUTRAL
SWITCH
1. Inspect:
• Neutral switch conduction
Not conductive while it is in neutral→
Replace.
Conductive while it is engaged→Re-
place.
Set the tester selection position to "Ω
× 1".
CHECKING THE CDI UNIT
Check all electrical components. If no
fault is found, replace the CDI unit.
Then check the electrical compo-
nents again.
ELECTRIC STARTING
SYSTEM
STARTING CIRCUIT CUT-OFF
SYSTEM OPERATION
If the main switch is set to "ON", the
starter motor can only operate if at
least one of the following conditions is
met:
• The transmission is in neutral (the
neutral switch is closed).
• The clutch lever is pulled to the han-
dlebar (the clutch switch is closed).
The starting circuit cut-off relay pre-
vents the starter motor from operating
when neither of these conditions has
been met. In this instance, the start-
ing circuit cut-off relay is open so cur-
rent cannot reach the starter motor.
When at least one of the above con-
ditions has been met the starting cir-
cuit cut-off relay is closed and the
engine can be started by pressing the
start switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR1. Battery
2. Main fuse
3. Main switch
4. Starting circuit cut-off relay
5. Start switch
6. Diode
7. Clutch switch
8. Neutral switch
9. Starter relay
10. Starter motor Tester (+) lead→Orange lead "1"
Tester (-) lead→Spark plug termi-
nal "2"
Secondary
coil resis-
tanceTester se-
lector posi-
tion
4.6–6.8
kΩat 20 °C
(68 °F) kΩ × 1
Tester (+) lead→Red lead "1"
Tester (-) lead→White lead "2"
Pickup coil
resistanceTester se-
lector posi-
tion
248–372 Ω
at 20 °C (68
°F) Ω × 100
Tester (+) lead→Sky blue lead "1"
Tester (-) lead→Ground "2"
Result
Conductive (while gear
is in neutral)

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

7-17
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"

7-18
THROTTLE POSITION SENSOR SYSTEM
9. Adjust:
• Throttle position sensor output
voltage
Adjustment steps:
a. Adjust the installation angle of the
throttle position sensor "1" to ob-
tain the specified output voltage.
Measure the output voltage accurate-
ly with a digital electronic voltmeter
that gives an easy reading of a small
voltage.
10. Put the aligning marks "a" on the
throttle position sensor and car-
buretor.
11. Stop the engine.
12. Remove the carburetor.
13. Tighten:
• Screw (throttle position sensor)
"1"
Tighten the screw (throttle position
sensor) using the T25 bit.
14. Install the carburetor.CHECKING THE THROTTLE
POSITION SENSOR INPUT
VOLTAGE
1. Disconnect the throttle position
sensor coupler.
2. Start the engine.
3. Inspect:
• Throttle position sensor input volt-
age
Out of specification→Replace the
CDI unit.
Throttle po-
sition sen-
sor output
voltageTester se-
lector posi-
tion
0.58–0.78 V DCV
Tester (+) lead→Blue lead "1"
Tester (-) lead→Black/Blue lead
"2"
Throttle po-
sition sen-
sor input
voltage Tester se-
lector posi-
tion
4–6 V DCV-20