2004 YAMAHA WR 450F charging

5 - 60
CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:1 Rear shock absorber removal2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is nodanger of it falling over.
Seat, fitting band and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
Air filter cover Refer to “AIR FILTER CLEANING” sec-
tion in the CHAPTER 3.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Coolant reservoir tank breather
hoseDisconnect at the coolant reservoir tank
side.
Coolant reservoir hose Disconnect at the coolant reservoir tank
side.
Battery Refer to “BATTERY INSPECTION AND
CHARGING” section in the CHAPTER 3.

–+ELEC

6 - 3
IGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Only when the ignition checker is used.
NOTE:


Remove the following parts before inspection.
1) Seat
2) Fuel tank

Use the following special tools in this inspection.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112
*1 Check fuse.Replace fuse and
check wire harness.
*2 Check battery Recharge or replace.
Spark gap test*3 Clean or replace
spark plug.
Check entire ignition
system for connection.
(couplers, leads and
ignition coil)Repair or replace.
Check “ENGINE STOP”
button.Replace.
Check main switch. Replace.
Check ignition coil. Primary coil Replace.
Secondary coil Replace.
Check AC magneto. Pick-up coil Replace.
Check neutral switch. Repair or replace.
Replace CDI unit.
OK
OK
No spark
OK
OK
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good
No good
No good
No good

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6 - 8
ELECTRIC STARTING SYSTEM
INSPECTION STEPS
If the starter motor will not operate, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Refer to “MAIN SWITCH INSPECTION” section.
*4 marked: Refer to “NEUTRAL SWITCH INSPECTION” section.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Rear fender
Use 12 V battery in this inspection.
Use the following special tools in this inspection.
Pocket tester:
YU-3112-C/90890-03112
*1 Check fuseReplace fuse and
check wire harness.
*2 Check battery Recharge or replace.
Check each coupler and
wire connection.Repair or replace.
*3 Check main switch. Replace.
Check starter motor
operation.Repair or replace.
Check starting circuit
cut-off relay.Replace.
Check starter relay. Replace.
*4 Check neutral switch. Replace.
Check clutch switch. Replace.
Check diode. Replace.
Check start switch. Replace.
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good

–+ELEC
6 - 17
CHARGING SYSTEM
EC680000
CHARGING SYSTEM
EC681001
INSPECTION STEPS
If the battery is not charged, use the following inspection steps.
*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
NOTE:
Remove the following parts before inspection.
1) Seat
2) Fuel tank
Use the following special tool in this inspection.
Pocket tester:
YU-3112-C/90890-03112
*1 Check fuse.Replace fuse and
check wire harness.
*2 Check battery. Recharge or replace.
Check each coupler and
wire connection.Repair or replace.
Check charging voltage.Charging system is
good.
Check AC magneto. Charging coil Replace.
Replace rectifier/regulator.
OK
OK
OK
No good
OK
No good
No good
No good
No good
OK

6 - 18
–+ELECCHARGING SYSTEM
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
CHARGING VOLTAGE INSPECTION
1. Start the engine.
2. Inspect:
Charging voltage
Out of specification → If no failure is
found in checking the source coil resis-
tance, replace the rectifier/regulator.
Tester (+) lead → Red lead 1
Tester (–) lead → Black lead 2
Charging
voltageTester selector
position
14.1 ~ 14.9 V at
5,000 r/minDCV-20
R
BW Y1
2
3. Inspect:
Charging coil resistance
Out of specification → Replace.
Tester (+) lead → White lead 1
Tester (–) lead → Ground 2
Charging coil
resistanceTester selector
position
0.288 ~ 0.432 Ω
at 20 ˚C (68 ˚F)Ω × 1