2002 YAMAHA WR 426F ignition

CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM
...........................6-1
MAP-CONTROLLED CDI UNIT
.................6-2
IGNITION SYSTEM
....................................6-3
TPS (THROTTLE POSITION
SENSOR) SYSTEM
...................................6-7
LIGHTING SYSTEM
................................6-12
CHAPTER 7
TUNING
ENGINE
......................................................7-1
CHASSIS
.................................................7-11

1 - 8
GEN
INFO
SPECIAL TOOLS
YU-33975, 90890-01403 Ring nut wrench
This tool is used when tighten the steering ring nut to
specification.YU-33975 90890-01403
YM-1423, 90890-01423 Damper rod holder
Use this tool to remove and install the damper rod.YM-1423 90890-01423
YM-01442, 90890-01442 Fork seal driver
This tool is used when install the fork oil seal.YM-01442 90890-01442
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-3112-C 90890-03112
YU-8036-B
90890-03113Inductive tachometer
Engine tachometer
This tool is needed for observing engine rpm.YU-8036-B 90890-03113
YM-33277-A, 90890-03141 Timing light
This tool is necessary for checking ignition timing.YM-33277-A 90890-03141
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-4019 90890-04019
YM-91042, 90890-04086 Clutch holding tool
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.YM-91042 90890-04086
YM-4116, 90890-04116
YM-4097, 90890-04097Valve guide remover
Intake (4.5 mm)
Exhaust (5.0 mm)
This tool is needed to remove and install the valve
guide.YM-4116
YM-409790890-04116
90890-04097
Part number Tool name/How to use Illustration

1 - 9
GEN
INFO
SPECIAL TOOLS
YM-4117, 90890-04117
YM-4098, 90890-04098Valve guide installer
Intake
Exhaust
This tool is needed to install the valve guide.YM-4117
YM-409890890-04117
90890-04098
YM-4118, 90890-04118
YM-4099, 90890-04099Valve guide reamer
Intake (4.5 mm)
Exhaust (5.0 mm)
This tool is needed to rebore the new valve guide.YM-4118
YM-409990890-04118
90890-04099
YM-34487
90890-06754Dynamic spark tester
Ignition checker
This instrument is necessary for checking the ignition
system components.YM-34487 90890-06754
ACC-QUICK-GS-KT
90890-85505Quick gasket

YAMAHA Bond No. 1215
This sealant (Bond) is used for crankcase mating
surface, etc.ACC-QUICK-GS-KT 90890-85505
Part number Tool name/How to use Illustration

2 - 3
SPECGENERAL SPECIFICATIONS (WR426F)
Tire:
Type With tube
Size (front) 80/100-21 51M (USA, CDN, ZA)
90/90-21 54R (EUROPE, AUS, NZ)
Size (rear) 110/100-18 64M (USA, CDN, ZA)
130/90-18 69R (EUROPE, AUS, NZ)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity:
Headlight 12 V 60/55 W × 1
Tail light 12 V 21/5 W × 1

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SPECMAINTENANCE SPECIFICATIONS (WR426F)
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufacturer 5NG-50/YAMAHA ----
Source coil 1 resistance (color) 640 ~ 960 Ω at 20 ˚C (68 ˚F)
(Green – Brown)----
Source coil 2 resistance (color) 464 ~ 696 Ω at 20 ˚C (68 ˚F)
(Green – Pink)----
Lighting coil resistance (color) 0.16 ~ 0.24 Ω at 20 ˚C (68 ˚F)
(Black – Yellow)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)
(White – Red)----
CDI unit-model/manufacturer 5NG-50/YAMAHA
(For USA)
5NG-60/YAMAHA
(Except for USA)----
----
Ignition coil:
Model/manufacturer 5BE-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.20 ~ 0.30 Ω at 20 ˚C (68 ˚F) ----
Secondary winding resistance 9.5 ~ 14.3 kΩ at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M10 × 1.25 1 48 4.8 35
Ignition coil M6 × 1.0 2 7 0.7 5.1

2 - 20
SPECGENERAL SPECIFICATIONS (WR400F)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity:
Headlight 12 V 60/55 W × 1
Tail light 12 V 21/5 W × 1

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SPECMAINTENANCE SPECIFICATIONS (WR400F)
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufacturer 5NG-50/YAMAHA ----
Source coil 1 resistance (color) 640 ~ 960 Ω at 20 ˚C (68 ˚F)
(Green – Brown)----
Source coil 2 resistance (color) 464 ~ 696 Ω at 20 ˚C (68 ˚F)
(Green – Pink)----
Lighting coil resistance (color) 0.16 ~ 0.24 Ω at 20 ˚C (68 ˚F)
(Black – Yellow)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)
(White – Red)----
CDI unit-model/manufacturer 5GS-A0/YAMAHA ----
Ignition coil:
Model/manufacturer 5BE-00/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.20 ~ 0.30 Ω at 20 ˚C (68 ˚F) ----
Secondary winding resistance 9.5 ~ 14.3 kΩ at 20 ˚C (68 ˚F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M10 × 1.25 1 48 4.8 35
Ignition coil M6 × 1.0 2 7 0.7 5.1

2 - 39
SPECCABLE ROUTING DIAGRAM
ÈMake sure that the TPS read
coupler does not go outside
the chassis.
ÔFasten the TPS lead under the
coupler to the frame with a
plastic locking tie.
Pass the carburetor breather
hoses and overflow hose
between the connecting rod
and cross tube (frame).
ÒFasten the neutral switch lead
and oil hose together with a
plastic locking tie and cut off
the tie end.
˜Fasten the cylinder head
breather hose with the hose
holder.
ˆFasten the neutral switch lead
to the frame with a plastic
band ends toward the rear of
the frame.ØFasten the neutral switch lead
and CDI magneto lead
together with a plastic band.
∏Pass the clutch cable through
the cable guide.
ŒPass the cylinder head
breather hose along the inner
side of the radiator pipe.
ÂPass the clutch cable between
the frame and radiator and
over the lower boss on the
radiator.
ÍPass the neutral switch lead
and CDI magneto lead through
the cable guide and over the
middle radiator mounting boss.
Then, pass the decompression
cable under the middle radia-
tor mounting boss and along
the left side of the neutral
switch lead and CDI magneto
lead.ÊPass the clutch cable through
the cable guide.
ËFit the brake hose into the
guides on the protector.
◊Fasten the ignition coil lead
(in the sub wire harness) on
the upper inside of the frame
and cut off the tie end.
„Pass the ignition coil lead (in
the sub wire harness) under
the cushion bracket (frame).
≈Fasten the ignition coil lead
(in the sub wire harness) to
the frame with a plastic lock-
ing tie and cut off the tie end.
ÁPass the carburetor breather
hoses, overflow hose and
coolant reservoir tank
breather hose so that all there
hoses do not contact the rear
shock absorber.