User manual YAMAHA WR450 SERVICE MANUAL 2003

[. . . ] OWNER'S SERVICE MANUAL WR450FR LIT-11626-16-43 5TJ-28199-10 EC010000 WR450FR OWNER'S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U. S. A. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U. S. A. LIT-11626-16-43 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha's vast experience in the production of pacesetting racing machines. [. . . ] Inspect: G Push rod 1 1 G Bearing 2 G Plain washer 3 G Push rod 2 4 G Ball 5 Wear/damage/bend Replace. 4 - 51 CLUTCH EC4A5000 ENG a 2 1 ASSEMBLY AND INSTALLATION Push lever 1. Install: G Push lever 1 G Bolt (push lever) 10 Nm (1. 0 m · kg, 7. 2 ft · lb) NOTE: G Apply the lithium soap base grease on the oil seal lip. G Fit the seat plate 2 in the groove a of the push lever and tighten the bolt (seat plate). Clutch 1. Install: G Primary driven gear 1 G Thrust washer 2 G Clutch boss 3 NOTE: Apply the engine oil on the primary driven gear inner circumference. 2. Install: New G Lock washer 1 G Nut (clutch boss) 2 75 Nm (7. 5 m · kg, 54 ft · lb) NOTE: Use the clutch holding tool 3 to hold the clutch boss. Clutch holding tool: YM-91042/90890-04086 Å i Å For USA and CDN i Except for USA and CDN R. Install: G Friction plate 1 G Clutch plate 2 NOTE: G Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. Install: G Bearing 1 G Plain washer 2 New G Circlip 3 To push rod 1 4. Install: G Push rod 2 1 G Ball 2 G Push rod 1 3 NOTE: Apply the engine oil on the push rod 1, 2 and ball. 7. Install: G Clutch spring G Bolt (clutch spring) ENG 8 Nm (0. 8 m · kg, 5. 8 ft · lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 9. Install: G Clutch cover 1 G Bolt (clutch cover) 10 Nm (1. 0 m · kg, 7. 2 ft · lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. R. T. New 4 - 54 OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal: 1 Oil filter removal 3 Crankcase cover (right) removal Order Part name OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) REMOVAL Drain the engine oil. Exhaust pipe Brake pedal Clutch cover Oil filter cover Oil filter Coolant pipe 2 Water pump housing Pin Oil delivery pipe 4 - 55 Q'ty 2 Water pump removal Remarks Extent of removal Preparation for removal Refer to "ENGINE OIL REPLACEMENT" section in the CHAPTER 3. 1 1 1 1 2 1 1 3 2 1 2 3 4 5 6 OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ENG Extent of removal Order 7 8 9 10 11 12 13 14 15 16 17 Part name Oil hose Kickstarter Crankcase cover (right) Gasket Dowel pin/O-ring Impeller Plain washer Impeller shaft Oil seal 1 Oil seal 2 Bearing Q'ty 1 1 1 1 4/2 1 1 1 1 1 1 Remarks 2 3 2 Refer to "REMOVAL POINTS". 4 - 56 OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) REMOVAL POINTS EC4G3110 ENG Impeller shaft 1. Remove: G Impeller 1 G Plain washer 2 G Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil. Remove: G Bearing 1 G Oil seal 2 INSPECTION EC444200 Impeller shaft 1. Fur deposits Clean. 4 - 57 OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4H4600 ENG Bearing 1. Inspect: G Oil seal Wear/damage Replace. ASSEMBLY AND INSTALLATION EC4G5110 Oil seal 1. Install: G Oil seal 1 New NOTE: G Apply the lithium soap base grease on the oil seal lip. G Install the oil seal with its manufacture's marks or numbers facing inward. Install: G Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. 4 - 58 OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4G5220 ENG Impeller shaft 1. [. . . ] Run with the rebound damping adjuster 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 correction, turn the low compression damping adjuster on the softer side. * 7 - 17 SETTING CAUTION: TUN When using a rear cushion other than currently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Length a of standard shock: 490. 5 mm (19. 31 in) Å Coverage of spring by weight i Rider weight 1 Soft 2 Standard 3 Stiff 7 - 18 SETTING EC72Q000 TUN Rear shock absorber setting parts G Rear shock spring 1 [Equal pitch spring] TYPE I. D. [. . . ]