2003 YAMAHA WR 450F key

EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
WARNING
CAUTION:

EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of seven chapters;
“General Information”, “Specifications”,
“Regular inspection and adjustments”,
“Engine”, “Chassis”, “Electrical” and
“Tuning”.
2. The table of contents is at the beginning
of the manual. Look over the general lay-
out of the book before finding then
required chapter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol mark
and go to a page for required item and
description.

3 - 12
INSP
ADJ
AIR FILTER CLEANING
AIR FILTER CLEANING
NOTE:
Proper air filter maintenance is the biggest key
to preventing premature engine wear and
damage.
CAUTION:
Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.
1. Remove:
Air filter case cover 1
NOTE:
Loosen the quick screw 2 and draw the air fil-
ter case cover to remove it because its claws
a are inserted in the side cover as shown.
2. Unhook:
Binder 1
3. Remove:
Air filter element 1
Filter guide 2
4. Clean:
Air filter element
Clean them with solvent.
NOTE:
After cleaning, remove the remaining solvent
by squeezing the element.

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

4 - 78
ENGAC MAGNETO AND STARTER CLUTCH
EC4L3000
REMOVAL POINTS
Rotor
1. Remove:
Nut (rotor) 1
Plain washer
2. Remove:
Rotor 1
Use the rotor puller 2.
Rotor puller:
YM-04141/90890-04141
EC4L4000
INSPECTION
AC magneto
1. Inspect:
Rotor inner surface a
Stator outer surface b
Damage → Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace AC magneto and/
or stator.
EC4L4200
Woodruff key
1. Inspect:
Woodruff key 1
Damage → Replace.

4 - 80
ENGAC MAGNETO AND STARTER CLUTCH
2. Install:
Holder 1
Bolt 2
NOTE:
Pass the pick-up coil lead 3 and AC mag-
neto lead 4 under the holder as shown.
Take care not to catch the AC magneto lead
between crankcase cover ribs.
Apply the sealant to the grommet of the AC
magneto lead.
Quick gasket:
ACC-QUICK-GS-KT
YAMAHA Bond No. 1215:
90890-85505
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
Plain washer 1
Bearing 2
Starter clutch drive gear 3
Starter clutch 4
NOTE:
Apply the engine oil on the plain washer, bear-
ing and starter clutch drive gear inner circum-
ference.
4. Install:
Woodruff key 1
Rotor 2
NOTE:
Clean the tapered portions of the crankshaft
and 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 rotor, align the keyway c
of the rotor with the woodruff key.
c
2 1 1
ba