Yamaha Wr 450 F Owners Manual

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ENGOIL PUMP
2. Install:
Outer rotor 1 1 
NOTE:
Apply the engine oil on the outer rotor 1.
3. Install:
Oil pump cover 1 
Screw (oil pump cover) 2 
Pin 3 
Inner rotor 2 4 
Circlip 5 
NOTE:
Apply the engine oil on the oil pump drive
shaft end and inner rotor 2.
Fit the pin into the groove in the inner rotor 2.
4. Install:
Outer rotor 2 1 
Dowel pin 2 
Oil pump assembly 3 
Bolt (oil pump assembly) 
[L = 30 mm (1.18 in)] 4 
Bolt (oil pump assembly) 
[L = 25 mm (0.98 in)] 5 
NOTE:
Apply the engine oil on the outer rotor 2.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
5. Install:
Oil pump drive gear 1 
Plate washer 2 
Circlip 3 
NOTE:
Apply the engine oil on the oil pump drive gear
inner circumference.
New 
						

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ENGKICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
Extent of removal:1 Kick axle removal2 Kick axle disassembly
3 Shift shaft removal4 Segment removal
Extent of removal Order Part name Q’ty Remarks
KICK AXLE AND SHIFT SHAFT 
REMOVAL
Preparation for removal Oil pump Refer to “OIL PUMP” section.
1 Kick idle gear 1
2 Kick axle assembly 1 Refer to “REMOVAL POINTS”.
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick axle 1
8 Plain washer 1
9 Shift pedal 1
10 Shift shaft 1
11 Collar 1
12 Torsion spring 1
3
2
1
4
1 
						

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ENGKICK AXLE AND SHIFT SHAFT
Extent of removal Order Part name Q’ty Remarks
13 Roller 1
14 Shift guide 1
Refer to “REMOVAL POINTS”.
15 Shift lever assembly 1
16 Shift lever 1
17 Pawl 2
18 Pawl pin 2
19 Spring 2
20 Bolt (stopper lever) 1
21 Stopper lever 1
22 Torsion spring 1
23 Segment 1 Refer to “REMOVAL POINTS”.
4 
						

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ENGKICK AXLE AND SHIFT SHAFT
REMOVAL POINTS
EC4B3101
Kick axle assembly
1. Remove:
Kick axle assembly 1 
NOTE:
Unhook the torsion spring 2 from the hole a
in the crankcase.
EC4C3101
Shift guide and shift lever assembly
1. Remove:
Bolt (shift guide)
Shift guide 1 
Shift lever assembly 2 
NOTE:
The shift lever assembly is disassembled at
the same time as the shift guide.
EC4N3100
Segment
1. Remove:
Bolt (segment) 1 
Segment 2 
NOTE:
Turn the segment counterclockwise until it
stops and loosen the bolt.
INSPECTION
EC4C4200
Kick axle and ratchet wheel
1. Check:
Ratchet wheel 1 smooth movement
Unsmooth movement → Replace.
Kick axle 2 
Wear/damage → Replace.
Spring 3 
Broken → Replace.
EC4C4300
Kick gear, kick idle gear and ratchet wheel
1. Inspect:
Kick gear 1 
Kick idle gear 2 
Ratchet wheel 3 
Gear teeth a 
Ratchet teeth b 
Wear/damage → Replace. 
						

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ENGKICK AXLE AND SHIFT SHAFT
EC4B4400
Shift shaft
1. Inspect:
Shift shaft 1 
Bend/damage → Replace.
Spring 2 
Broken → Replace.
EC4C4100
Shift guide and shift lever assembly
1. Inspect:
Shift guide 1 
Shift lever 2 
Pawl 3 
Pawl pin 4 
Spring 5 
Wear/damage → Replace.
EC4B4500
Stopper lever
1. Inspect:
Stopper lever 1 
Wear/damage → Replace.
Torsion spring 2 
Broken → Replace.
EC4C5000
ASSEMBLY AND INSTALLATION
Segment
1. Install:
Segment 1 
Bolt (segment) 
NOTE:
Align the notch a on the segment with the pin
b on the shift cam.
T R..30 Nm (3.0 m · kg, 22 ft · lb) 
						

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ENGKICK AXLE AND SHIFT SHAFT
EC4B5111
Stopper lever
1. Install:
Torsion spring 1 
Stopper lever 2 
Bolt (stopper lever) 3 
NOTE:
Align the stopper lever roller with the slot on
segment.
Shift guide and shift lever assembly
1. Install:
Spring 1 
Pawl pin 2 
Pawl 3 
To shift lever 4.
NOTE:
Apply the engine oil on the springs, pawl pins
and pawls.
2. Install:
Shift lever assembly 1 
To shift guide 2.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
2
1
3. Install:
Shift lever assembly 1 
Shift guide 2 
NOTE:
The shift lever assembly is installed at the
same time as the shift guide.
Apply the engine oil on the bolt (segment)
shaft.
4. Install:
Bolt (shift guide) 1 
T R..10 Nm (1.0 m · kg, 7.2 ft · lb) 
						

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ENGKICK AXLE AND SHIFT SHAFT
EC4C5301
Shift shaft
1. Install:
Roller 1 
Collar 2 
Torsion spring 3 
Shift shaft 4 
NOTE:
Apply the engine oil on the roller and shift
shaft.
2. Install:
Shift pedal
Refer to “AC MAGNETO AND 
STARTER CLUTCH” section.
Kick axle assembly
1. Install:
Kick gear 1 
Plain washer 2 
Circlip 3 
Ratchet wheel 4 
Spring 5 
Plain washer 6 
Circlip 7 
To kick axle 8.
NOTE:
Apply the molybdenum disulfide oil on the
inner circumferences of the kick gear and
ratchet wheel.
Align the punch mark a on the ratchet wheel
with the punch mark b on the kick axle.
New
New
2. Install:
Torsion spring 1 
To kick axle 2.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole b on the kick axle. 
						

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ENGKICK AXLE AND SHIFT SHAFT
3. Install:
Spring guide 1 
NOTE:
Slide the spring guide into the kick axle, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
4. Install:
Kick axle assembly 1 
Plain washer 2 
NOTE:
Apply the molybdenum disulfide grease on
the contacting surfaces of the kick axle stop-
per a and stopper plate 3.
Apply the engine oil on the kick axle.
Slide the kick axle assembly into the crank-
case and make sure the kick axle stopper fits
into the stopper plate.
5. Hook:
Torsion spring 1 
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
Kick idle gear
1. Install:
Kick idle gear 1 
Plain washer 2 
Circlip 3 
NOTE:
Install the kick idle gear with its depressed
side a toward you.
Apply the engine oil on the kick idle gear
inner circumference.
New 
						

							 
4 - 76
ENG
 
AC MAGNETO AND STARTER CLUTCH
AC MAGNETO AND STARTER CLUTCH 
Extent of removal:  
1  
 Starter clutch/wheel gear removal  
2  
 Rotor removal  
3  
 Pickup coil/stator removal
Extent of removal Order Part name Q’ty Remarks  
AC MAGNETO AND STATOR 
REMOVAL  
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” 
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE 
COVERS” section.
Bolt [radiator (left)]
Disconnect the AC magneto lead.Refer to “RADIATOR” section.
1 Shift pedal 1
2 Engine guard (left) 1
3 Cover (idle gear 1) 1
4 Idle gear 1 1
5 Bearing 1
6 Shaft 1
7 Crankcase cover (left) 1
8 Gasket 1
31 
						

							 
4 - 77
ENG
 
AC MAGNETO AND STARTER CLUTCH
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). 
Extent of removal Order Part name Q’ty Remarks
9 Dowel pin 2
10 Idle gear 2 1
11 Bearing 1
12 Shaft 1
13* Nut (rotor) 1 Refer to NOTE.
14 Rotor 1 Use special tool.
Refer to “REMOVAL POINTS”.
15 Woodruff key 1
16 Starter clutch 1
17 Starter clutch drive gear 1
18 Bearing 1
19 Plain washer 1
20 Holder 1
21 Pick-up coil 1
22 Stator 1
3
21
3