2004 YAMAHA WR 450F torque

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ENGAC MAGNETO AND STARTER CLUTCH
Starter clutch
1. Check:
Starter clutch
Damage/wear → Replace.
2. Check:
Idle gear
Idle gear shaft
Starter clutch gear
Pitting/burrs/chips/roughness/wear →
Replace the defective parts.
3. Check:
Starter clutch operation
Install the starter clutch drive gear 1 onto
the starter clutch 2 and hold the starter
clutch.
When turning the starter clutch drive gear
counterclockwise ı, the starter clutch and
the starter clutch drive gear should
engage. If the starter clutch drive gear and
starter clutch do not engage, the starter
clutch is faulty and must be replaced.
When turning the starter clutch drive gear
clockwise Å, it should turn freely.
If the starter clutch drive gear does not
turn freely, the starter clutch is faulty and
must be replaced.
Torque limiter
1. Check:
Torque limiter
Damage/wear → Replace.
EC4L5000
ASSEMBLY AND INSTALLATION
AC magneto and starter clutch
1. Install:
Stator 1
Bolt (stator) 2
Pick-up coil 3
Bolt (pick-up coil) 4
NOTE:
Pass the AC magneto lead 5 under the pick-
up coil.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4 - 81
ENG
5. Install:
Bolt (starter clutch) 1
Plain washer (rotor)
Nut (rotor) 2
Use the sheave holder 3.
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).
Sheave holder:
YS-1880-A/90890-01701
1
1
3
2
T R..16 Nm (1.6 m · kg, 11 ft · lb)
T R..65 Nm (6.5 m · kg, 47 ft · lb)
6. Install:
Shaft 1
Bearing 2
Idle gear 2 3
NOTE:
Apply the engine oil on the shaft, bearing and
idle gear inner circumference.
7. Install:
Dowel pin
Gasket [crankcase cover (left)]
Crankcase cover (left) 1
Bolt [crankcase cover (left)]
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
8. Install:
Plain washer
Torque limiter 1
Plain washer
NOTE:
Apply the engine oil to the shaft and plain
washers.1
AC MAGNETO AND STARTER CLUTCH

5 - 38
CHASFRONT FORK
26. Tighten:
Cap bolt (locknut) 1
NOTE:
While compressing the fork spring, set the
thin type spanners 2 between the spacer 3
and spring guide 4.
Hold the locknut 5 and tighten the cap bolt
with specified torque.
27. Install:
Cap bolt 1
To outer tube.
NOTE:
Temporarily tighten the cap bolt.
T R..29 Nm (2.9 m · kg, 21 ft · lb)
28. Install:
Protector guide 1
Installation
1. Install:
Front fork 1
NOTE:
Temporarily tighten the pinch bolts (under
bracket).
Do not tighten the pinch bolts (handle crown)
yet.
2. Tighten:
Cap bolt 1
3. Adjust:
Front fork top end a
Front fork top end (standard) a:
Zero mm (Zero in)
T R..30 Nm (3.0 m · kg, 22 ft · lb)

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CHASFRONT FORK
4. Tighten:
Pinch bolt (handle crown) 1
Pinch bolt (under bracket) 2
CAUTION:
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:
Brake hose holder 1
Caliper 2
Bolt (caliper) 3
NOTE:
Fit the brake hose holder cut a over the pro-
jection b on the front fork and clamp the brake
hose.
6. Install:
Brake hose holder 1
Bolt (brake hose holder) 2
Protector 3
Bolt (protector) 4
NOTE:
When installing the brake hose holder, align
the top a of the brake hose neck with the
brake hose holder bottom b. Then pass the
brake hose 5 in front of the axle boss c and
fit it into the hose groove d so that the brake
hose does not contact the nut (wheel axle).
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Adjust:
Rebound damping force
NOTE:
Turn in the damping adjuster 1 finger-tight
and then turn out to the originally set position.

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CHASSTEERING
9. Install:
Steering shaft cap 1
10. After tightening the nut, check the steer-
ing for smooth movement. If not, adjust
the steering by loosening the ring nut little
by little.
11. Adjust:
Front fork top end a
Front fork top end (standard) a:
Zero mm (Zero in)
12. Tighten:
Pinch bolt (handle crown) 1
Pinch bolt (under bracket) 2
CAUTION:
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
13. Install:
Trip meter 1
Bolt (trip meter) 2
NOTE:
Install the trip meter over the coupler bracket
3.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

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TUNSETTING
EC72H002
Suspension setting
Front fork
NOTE:
If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.
Before any change, set the rear shock absorber sunken length to the standard figure 90 ~
100 mm (3.5 ~ 3.9 in).
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff over entire range

Compression damping
Oil level (oil amount)
SpringTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with soft spring.
Unsmooth movement
over entire range

Outer tube
Inner tube
Under bracket tightening
torqueCheck for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Retighten to specified torque.
Poor initial
movement

Rebound damping
Oil sealTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Apply grease in oil seal wall.
Soft over entire range,
bottoming out

Compression damping
Oil level (oil amount)
SpringTurn adjuster clockwise (about 2 clicks) to increase
damping.
Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with stiff spring.
Stiff toward stroke end
Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke end,
bottoming out
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
Stiff initial movement
Compression dampingTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low front, tending to
lower front posture

Compression damping
Rebound damping
Balance with rear end
Oil level (oil amount)Turn adjuster clockwise (about 2 clicks) to increase
damping.
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when
one passenger is astride seat (lower rear posture).
Increase oil level by about 5 mm (0.2 in).
“Obtrusive” front, tend-
ing to upper front pos-
ture

Compression damping
Balance with rear end
Spring
Oil lever (oil amount)Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in) when
one passenger is astride seat (upper rear posture).
Replace with soft spring.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).