clutch YAMAHA WR 450F 2016 Service Manual

CLUTCH
6-49
EAS2GC1280INSTALLING THE KICKSTARTER LEVER
1. Install:• Kickstarter lever “1”
• Washer
• Bolt (kickstarter lever)
TIP
Install so that there is a clearance “a” of 5 mm
(0.2 in) or more between the kickstarter lever
and the frame and that the kickstarter lever
does not contact the right crankcase cover
when it is pulled. Bolt (kickstarter lever)
33 Nm (3.3 m·kgf, 24 ft·lbf)
LOCTITE®
1
T R..
1
a

KICKSTATER
6-50
EAS2GC1281
KICKSTATER
Removing the kick shaft
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
1 Kick idle gear 1
2 Kick shaft assembly 1
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick shaft 1
For installation, reverse the removal proce-
dure.

SHIFT SHAFT
6-53
EAS2GC1287
SHIFT SHAFT
Removing the shift shaft and stopper lever
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
1 Shift pedal 1
2 Shift shaft 1
3 Oil seal 1
4Collar 1
5 Shift shaft spring 1
6Roller 1
7 Shift guide 1
8 Shift lever assembly 1
9 Shift lever 1
10 Pawl 2
11 Pawl pin 2
12 Spring 2
13 Stopper lever 1
14 Stopper lever spring 1
15 Segment 1
For installation, reverse the removal proce-
dure.
LS
1
3
13
15
14
LT
6
10
11
12
11 8
12 10
4
2 5
LT
7
LT
E
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
30 Nm (3.0 m kgf, 22 ftT.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
Ibf)
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.

OIL PUMP AND BALANCER GEAR
6-57
EAS2GC1298
OIL PUMP AND BALANCER GEAR
Removing the oil pump
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
Right crankcase cover Refer to “CLUTCH” on page 6-41.
1 Oil pump assembly 1
2 Oil pump cover 1
3 Outer rotor 1
4 Dowel pin 1
5 Inner rotor 1
6 Oil pump drive shaft 1
7 Rotor housing 1
For installation, reverse the removal proce-
dure.
2.0 Nm (0.20 mkgf, 1.4 ftIbf)T.R.
5 Nm (0.5 mkgf, 3.6 ftIbf)T.R.
LT
E
3
2
1
4
5
7
6

OIL PUMP AND BALANCER GEAR
6-58
Removing the balancer
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
Right crankcase cover Refer to “CLUTCH” on page 6-41.
Generator rotor Refer to “GENERATOR AND STARTER
CLUTCH” on page 6-63.
1 Nut (balancer) 1
2 Nut (primary drive gear) 1
3 Nut (balancer shaft driven gear) 1
4 Lock washer 1
5Balancer 1
6 Straight key 1
7 Conical washer 1
8 Primary drive gear 1
9 Balancer shaft drive gear 1
10 Lock washer 1
11 Balancer weight gear 1
For installation, reverse the removal proce-
dure.
45 Nm (4.5 m kgf, 33 ft Ibf)T.R.
100 Nm (10 m kgf, 72 ft lbf)T.R.
50 Nm (5.0 m kgf, 36 ft Ibf)T.R.
New
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
11
LT

GENERATOR AND STARTER CLUTCH
6-63
EAS2GC1305
GENERATOR AND STARTER CLUTCH
Removing the generator
Order Job/Parts to remove Q’tyRemarks
Drain the engine oil. Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Seat and fuel tank Refer to “GENERAL CHASSIS” on page 5-1
and “FUEL TANK” on page 8-1.
Disconnect the AC magneto lead.
Clutch cable
Shift pedal Refer to “SHIFT SHAFT” on page 6-53.
1 Cover (Damper assembly) 1
2 Damper assembly 1
3 Left crankcase cover 1
4Gasket 1
5 Dowel pin 2
6 Starter idle gear 1
7 Bearing 1
8 Starter idle gear shaft 1
9 Generator rotor 1
10 Woodruff key 1
T R..
T R..
T R..
5
5 10
87
6
21
13 3
4
11 9
12
T R..
T R..
T R..LT
LT
T R..
T R..
14
LT
LT

GENERATOR AND STARTER CLUTCH
6-64
11 Starter clutch1
12 Starter clutch drive gear 1
13 Crankshaft position sensor 1
14 Stator 1
For installation, reverse the removal proce-
dure.
Removing the generator
Order Job/Parts to remove Q’tyRemarks
T R..
T R..
T R..
5
5 10
87
6
21
13 3
4
11 9
12
T R..
T R..
T R..LT
LT
T R..
T R..
14
LT
LT

GENERATOR AND STARTER CLUTCH
6-65
EAS2GC1306REMOVING THE GENERATOR
1. Remove:• Generator rotor nut “1”
• Washer
2. Remove: • Generator rotor “1”
(with the rotor puller “2”)
• Woodruff key
EAS2GC1307CHECKING THE STARTER CLUTCH
1. Check: • Starter clutch rollers
Damage/wear  Replace.
2. Check: • Starter clutch idle gear
• Starter clutch gearBurrs/chips/roughness/wear  Replace the
defective part (s). 3. Check:
• Starter clutch gearDamage/pitting/wear  Replace the starter
clutch gear.
4. Check: • Damper assembly
Damage/pitting/wear  Replace the damp-
er assembly.
Check the gear of the starter motor arma-
ture.
5. Check: • Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear “1” onto the starter clutch and hold the starter clutch.
b. When turning the starter clutch drive gear
clockwise “A”, the starter clutch and the
starter clutch drive gear should engage, oth-
erwise the starter clutch is faulty and must
be replaced.
c. When turning the starter clutch drive gear counterclockwise “B”, it should turn freely,
otherwise the starter clutch is faulty and
must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rotor puller90890-04142
Rotor puller YM-04142
1
1
2
1
A
B

GENERATOR AND STARTER CLUTCH
6-66
EAS2GC1308INSTALLING THE STARTER CLUTCH
1. Install:• Stator “1”
• Stator bolt “2”
• Crankshaft position sensor “3”
• Holder “4”
• Crankshaft position sensor bolt “5”
TIP
• Pass the stator coil lead between ribs “a”, and put it in part “b” so that there is no slack.
• Pass crankshaft sensor lead “c” over stator
coil lead “d”.
• Pass the crankshaft sensor lead outside of rib “a” and place the excess end next to boss “e”.
• Make sure that the end surface of holder “f” does not get caught on rib “a”.
• Place the stator coil lead and crankshaft sen-
sor lead inside the U-shaped space “g”of the
holder.
• Tighten the stator bolt using the T25 bit.
• Apply the sealant to the grommet of the AC
magneto lead. 2. Install
• Starter clutch drive gear “1”
TIP
Apply the engine oil on the starter clutch drive
gear inner circumference.
Stator bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LOCTITE®
Crankshaft position sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Yamaha bond No. 1215 90890-85505
(Three bond No.1215®)
T R..
T R..
g
d
c
ea
a
b
f
LT

GENERATOR AND STARTER CLUTCH
6-67
3. Install:• Starter clutch “1”To generator rotor “2”.
EAS2GC1309INSTALLING THE GENERATOR
1. Install:
• Woodruff key “1”
• Generator rotor “2”
TIP
• Clean the contact surfaces of the tapered por-tions of the crankshaft and generator rotor.
• When installing the woodruff key, make sure that its flat surface “a” is in parallel with the
crankshaft center line “b”.
• When installing the generator rotor, align the keyway “c” of the generator rotor with the
woodruff key.
2. Install: • Washer
• Generator rotor nut “1” 3. Install:
• Starter idle gear shaft “1”
• Bearing “2”
• Starter idle gear 2 “3”
TIP
Apply the engine oil on the starter idle gear
shaft, bearing and idle gear inner circumfer-
ence.
4. Install:
• Dowel pin
• Crankcase cover gasket
• Left crankcase cover “1”
• Lead holder “2”
• Crankcase cover bolt
• Neutral switch lead “3”
TIP
• Pass the AC magneto lead “4” under the left crankcase cover “a” as shown.
• Tighten the bolts in stage, using a crisscross
pattern.
Starter clutch bolt
16 Nm (1.6 m·kgf, 12 ft·lbf)
LOCTITE®
Generator rotor nut 65 Nm (6.5 m·kgf, 47 ft·lbf)
21
LT
T R..
2
C
1 1
1a
b
T R..
Crankcase cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
1
2 1
2
3
New
T R..