Yamaha Wr 450 F Owners Manual
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SPEC 2 - 4 MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in)---- Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in)---- Camshaft journal diameter 21.967 ~ 21.980 mm (0.8648 ~ 0.8654 in)---- Shaft-to-cap clearance 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in)0.08 mm (0.003 in) Cam dimensions Intake“A”31.200 ~ 31.300 mm (1.2283 ~ 1.2323 in)31.100 mm (1.2244 in) “B”22.550 ~ 22.650 mm (0.8878 ~ 0.8917 in)22.450 mm (0.8839 in) Exhaust“A”30.950 ~ 31.050 mm (1.2185 ~ 1.2224 in)30.850 mm (1.2146 in) “B”22.494 ~ 22.594 mm (0.8856 ~ 0.8895 in)22.394 mm (0.8817 in) Camshaft runout limit ---- 0.03 mm (0.0012 in) A B
SPEC 2 - 5 MAINTENANCE SPECIFICATIONS Cam chain: Cam chain type/No. of links 98XRH2010-118M/118 ---- Cam chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) IN 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in)---- EX 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in)---- Valve dimensions: “A” head diameter IN 26.9 ~ 27.1 mm (1.0591 ~ 1.0669 in)---- EX 27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in)---- “B” face width IN 2.26 mm (0.089 in) ---- EX 2.26 mm (0.089 in) ---- “C” seat width IN 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.6 mm (0.0630 in) EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.6 mm (0.0630 in) “D” margin thickness IN 1 mm (0.0394 in) 0.85 mm (0.033 in) EX 1 mm (0.0394 in) 0.85 mm (0.033 in) Stem outside diameter IN 4.475 ~ 4.490 mm (0.1762 ~ 0.1768 in)4.445 mm (0.1750 in) EX 4.965 ~ 4.980 mm (0.1955 ~ 0.1961 in)4.935 mm (0.1943 in) Guide inside diameter IN 4.500 ~ 4.512 mm (0.1772 ~ 0.1776 in)4.550 mm (0.1791 in) EX 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)5.050 mm (0.1988 in) Stem-to-guide clearance IN 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)0.08 mm (0.003 in) EX 0.020 ~ 0.047 mm (0.0008 ~ 0.0019 in)0.10 mm (0.004 in) Stem runout limit ---- 0.01 mm (0.0004 in) Item Standard Limit Head Diameter B Face WidthC Seat Width D Margin ThicknessA
SPEC 2 - 6 MAINTENANCE SPECIFICATIONS Valve spring: Free length IN 37.03 mm (1.46 in) 35.17 mm (1.38 in) EX 37.68 mm (1.48 in) 35.79 mm (1.41 in) Set length (valve closed) IN 27.87 mm (1.10 in) ---- EX 27.38 mm (1.08 in) ---- Compressed force (installed) IN 111.3 ~ 127.9 N at 27.87 mm (11.3 ~ 13.0 kg at 27.87 mm, 24.91 ~ 28.66 lb at 1.10 in)---- EX 127.4 ~ 146.4 N at 27.38 mm (13.0 ~ 14.9 kg at 27.38 mm, 28.66 ~ 32.85 lb at 1.08 in)---- Tilt limit IN ---- 2.5˚/ 1.61 mm (2.5˚/0.063 in) EX ---- 2.5˚/1.65 mm (2.5˚/0.065 in) Direction of winding (top view) IN Clockwise ---- EX Clockwise ---- Piston: Piston to cylinder clearance 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in)0.1 mm (0.004 in) Piston size “D”94.945 ~ 94.960 mm (3.738 ~ 3.739 in)---- Measuring point “H”8 mm (0.315 in) ---- Piston off-set 1 mm (0.0394 in) ---- Piston pin bore inside diameter 18.004 ~ 18.015 mm (0.7088 ~ 0.7093 in)18.045 mm (0.7104 in) Piston pin outside diameter 17.991 ~ 18.000 mm (0.7083 ~ 0.7087 in)17.971 mm (0.7075 in) Item Standard Limit * H D
SPEC 2 - 7 MAINTENANCE SPECIFICATIONS Piston rings: Top ring: Type Barrel ---- Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ---- End gap (installed) 0.20 ~ 0.30 mm (0.008 ~ 0.012 in)0.55 mm (0.022 in) Side clearance (installed) 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in)0.12 mm (0.005 in) 2nd ring: Type Taper ---- Dimensions (B × T) 1.00 × 3.35 mm (0.04 × 0.13 in) ---- End gap (installed) 0.35 ~ 0.50 mm (0.014 ~ 0.020 in)0.85 mm (0.033 in) Side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in)0.12 mm (0.005 in) Oil ring: Dimensions (B × T) 2.0 × 2.9 mm (0.08 × 0.11 in) ---- End gap (installed) 0.2 ~ 0.5 mm (0.01 ~ 0.02 in) ---- Crankshaft: Crank width “A”61.95 ~ 62.00 mm (2.439 ~ 2.441 in)---- Runout limit “C”0.03 mm (0.0012 in) 0.05 mm (0.002 in) Big end side clearance “D”0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in)0.50 mm (0.02 in) Small end free play “F”0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm (0.08 in) Balancer: Balancer drive method Gear ---- Air filter oil grade: Foam-air-filter oil or equivalent oil ----Item Standard Limit T B B T B T
SPEC 2 - 8 MAINTENANCE SPECIFICATIONS Clutch: Friction plate thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in)2.8 mm (0.110 in) Quantity 9 ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity 8 ---- Warp limit ---- 0.1 mm (0.004 in) Clutch spring free length 48.4 mm (1.91 in) 47.4 mm (1.87 in) Quantity 6 ---- Clutch housing thrust clearance 0.10 ~ 0.35 mm (0.0039 ~ 0.0138 in)---- Clutch housing radial clearance 0.010 ~ 0.044 mm (0.0004 ~ 0.0017 in)---- Clutch release method Inner push, cam push ---- Shifter: Shifter type Cam drum and guide bar ---- Guide bar bending limit ---- 0.05 mm (0.002 in) Kickstarter: Type Ratchet type ---- Carburetor: USAEUROPE, CDN, AUS, NZ, ZA I. D. mark 5TJ1 00 5TJ2 10 ---- Main jet (M.J) #150 #160 ---- Main air jet (M.A.J)ø2.0 ← ---- Jet needle - clip position (J.N) OBDUT-4 OBDUQ-4 ---- Cutaway (C.A) 1.5 ← ---- Pilot jet (P.J) #45 #48 ---- Pilot air jet (P.A.J) #70 #80 ---- Pilot outlet (P.O)ø0.9 ← ---- Pilot screw (example) (P.S) 1-3/4 1-1/2 ---- Bypass (B.P)ø1.0 ← ---- Valve seat size (V.S)ø3.8 ← ---- Starter jet (G.S) #65 ← ---- Leak jet (Acc.P) #70 #50 ---- Float height (F.H) 8 mm (0.31 in) ← ---- Engine idle speed 1,700 ~ 1,900 r/min ← ---- Intake vacuum 33.3 ~ 38.7 kPa (250 ~ 290 mmHg, 9.84 ~ 11.42 inHg) ← ---- Hot starter lever free play 3 ~ 6 mm (0.12 ~ 0.24 in) ← ---- Item Standard Limit
SPEC 2 - 9 MAINTENANCE SPECIFICATIONS Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance “A”0.12 mm or less (0.0047 in or less)0.20 mm (0.008 in) Tip clearance “B”0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in)0.24 mm (0.009 in) Side clearance 0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in)0.17 mm (0.007 in) Bypass valve setting pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm 2 , 5.69 ~ 11.38 psi)---- Cooling: Radiator core size Width 127.8 mm (5.0 in) ---- Height 260 mm (10.2 in) ---- Thickness 32 mm (1.26 in) ---- Radiator cap opening pressure 110 kPa (1.1 kg/cm 2 , 15.6 psi) ---- Radiator capacity (total) 0.78 L (0.69 Imp qt, 0.82 US qt) ---- Water pump Type Single-suction centrifugal pump ----Item Standard Limit
SPEC 2 - 10 MAINTENANCE SPECIFICATIONS Item Standard Lubrication chart: Pressure feed Splashed scavenge Oil strainer Oil pan Oil pump rotor 2 Oil pump rotor 1 Oil tank Oil filter Check ball Cylinder head Crank pinPiston pinPiston Drive axleMain axleTransmission gears Camshaft Valve lifter
SPEC 2 - 11 MAINTENANCE SPECIFICATIONS Part to be tightened Thread size Q’tyTightening torque Nm m·kg ft·lb Spark plug M10S × 1.0 1 13 1.3 9.4 Camshaft cap M6 × 1.0 10 10 1.0 7.2 Cylinder head blind plug screw M12 × 1.0 1 37 3.7 27 Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1 M8 × 1.25 1 15 1.5 11 (bolt) M10 × 1.25 4 Refer to NOTE.* 1 (nut) M6 × 1.0 2 10 1.0 7.2 Cylinder head cover M6 × 1.0 2 10 1.0 7.2 Cylinder M6 × 1.0 1 10 1.0 7.2 Timing chain tensioner M6 × 1.0 2 10 1.0 7.2 Tensioner cap bolt M6 × 1.0 1 7 0.7 5.1 Timing chain guide (rear) M6 × 1.0 2 10 1.0 7.2 Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4 (bolt) M8 × 1.25 1 24 2.4 17 Silencer M8 × 1.25 2 35 3.5 25 Silencer clamp M8 × 1.25 1 20 2.0 14 Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2 Spark arrester (for USA) M6 × 1.0 3 10 1.0 7.2 Silencer end pipe (for USA) M6 × 1.0 1 10 1.0 7.2 Carburetor joint clamp (cylinder head side) M5 × 0.8 1 3 0.3 2.2 Carburetor joint clamp (carburetor side) M4 × 0.7 1 3 0.3 2.2 Air filter case M6 × 1.0 2 8 0.8 5.8 Air filter joint clamp M6 × 1.0 1 3 0.3 2.2 Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9 Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9 Throttle cable (return) M12 × 1.0 1 11 1.1 8.0 Throttle cable cover M5 × 0.8 2 4 0.4 2.9 Hot starter plunger M12 × 1.0 1 2 0.2 1.4 Radiator panel (upper) M6 × 1.0 2 10 1.0 7.2 Radiator M6 × 1.0 6 10 1.0 7.2 Radiator hose clamp M6 × 1.0 8 2 0.2 1.4 Radiator pipe 1, 2 M10 × 1.0 2 10 1.0 7.2 Impeller M8 × 1.25 1 14 1.4 10 Water pump housing cover M6 × 1.0 3 10 1.0 7.2 Coolant drain bolt M6 × 1.0 1 10 1.0 7.2 Oil pump cover M4 × 0.7 1 2 0.2 1.4 Oil pump M6 × 1.0 3 10 1.0 7.2 Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2 Oil filter cover M6 × 1.0 2 10 1.0 7.2 Oil delivery pipe 1 M10 × 1.25 1 20 2.0 14 M8 × 1.25 2 18 1.8 13 Oil delivery pipe 2 M6 × 1.0 1 10 1.0 7.2 Oil hose M6 × 1.0 2 10 1.0 7.2
SPEC 2 - 12 MAINTENANCE SPECIFICATIONS NOTE: - marked portion shall be checked for torque tightening after break-in or before each race. NOTE: *1: Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m · kg, 14 ft · lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180˚ in the proper tightening sequence.Oil check bolt M6 × 1.0 1 10 1.0 7.2 Oil hose clamp–2 2 0.2 1.4 Clutch cover M6 × 1.0 7 10 1.0 7.2 Crankcase cover (right) M6 × 1.0 10 10 1.0 7.2 Crankcase cover (left) M6 × 1.0 9 10 1.0 7.2 Idle gear cover (starter motor) M6 × 1.0 2 10 1.0 7.2 Crankcase M6 × 1.0 12 12 1.2 8.7 Clutch cable holder M6 × 1.0 1 10 1.0 7.2 Oil drain bolt (crankcase rear) M10 × 1.25 1 20 2.0 14 (crankcase left) M6 × 1.0 1 10 1.0 7.2 Oil drain bolt (frame) M8 × 1.25 1 23 2.3 17 Oil strainer (frame) M18 × 1.5 1 90 9.0 65 Crankcase bearing stopper M6 × 1.0 15 10 1.0 7.2 Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2 Ratchet wheel guide M6 × 1.0 2 12 1.2 8.7 Stopper plate M6 × 1.0 2 12 1.2 8.7 Kickstarter M8 × 1.25 1 33 3.3 24 Screw (kickstarter) M6 × 1.0 1 7 0.7 5.1 Starter clutch M6 × 1.0 6 16 1.6 11 Primary drive gear M20 × 1.0 1 75 7.5 54 Clutch boss M20 × 1.0 1 75 7.5 54 Push lever M6 × 1.0 1 10 1.0 7.2 Clutch spring M6 × 1.0 6 8 0.8 5.8 Balancer driven gear M14 × 1.0 1 50 5.0 36 Balancer weight plate M6 × 1.0 3 10 1.0 7.2 Drive sprocket M20 × 1.0 1 75 7.5 54 Drive sprocket cover M6 × 1.0 2 8 0.8 5.8 Shift pedal M6 × 1.0 1 12 1.2 8.7 Shift guide M6 × 1.0 2 10 1.0 7.2 Stopper lever M6 × 1.0 1 10 1.0 7.2 Segment M8 × 1.25 1 30 3.0 22 Part to be tightened Thread size Q’tyTightening torque Nm m·kg ft·lb
SPEC 2 - 13 MAINTENANCE SPECIFICATIONS EC212201 CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE AUS, NZ, ZA Front fork travel 300 mm (11.8 in)←← Fork spring free length 460 mm (18.1 in)←← Spring rate, STD K = 4.51 N/mm (0.46 kg/mm, 25.8 lb/in)K = 4.12 N/mm (0.42 kg/mm, 23.5 lb/in)K = 4.31 N/mm (0.44 kg/mm, 24.6 lb/in) Optional spring/spacer Yes←← Oil capacity 573 cm 3 (20.2 lmp oz, 19.4 US oz) ←← Oil level 130 mm (5.12 in)←← (From top of outer tube with inner tube and damper rod fully com- pressed without spring.)80 ~ 150 mm (3.15 ~ 5.91 in)←← Oil grade Suspension oil “01”←← Inner tube outer diameter 46 mm (1.81 in)←← Front fork top endZero mm (Zero in)←← Rear suspension: USA, CDN EUROPE AUS, NZ, ZA Shock absorber travel 132 mm (5.20 in)←← Spring free length260 mm (10.24 in)←← Fitting length 246 mm (9.69 in)246.5 mm (9.70 in)← 240.5 ~ 258.5 mm (9.47 ~ 10.18 in)←← Spring rate, STD K = 51.0 N/mm (5.20 kg/mm, 291.2 lb/in)K = 48.0 N/mm (4.90 kg/mm, 274.4 lb/in)K = 52.0 N/mm (5.30 kg/mm, 296.8 lb/in) Optional spring Yes←← Enclosed gas pressure 1,000 kPa (10 kg/cm2, 142 psi) ←← Swingarm: Swingarm free play limit End ---- 1.0 mm (0.04 in)