2005 YAMAHA WR 450F relay

5 - 56
CHASSWINGARM
3. Install:
Bearing 1
Oil seal 2
To connecting rod.
NOTE:
Apply the molybdenum disulfide grease on
the bearing when installing.
Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of bearings
a:
5 mm (0.20 in)
Swingarm
1. Install:
Bush 1
Thrust bearing 2
Oil seal 3
Collar 4
To swingarm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bushes, thrust bearings, oil seal lips and con-
tact surfaces of the collar and thrust bearing.
2. Install:
Collar 1
Washer 2
To relay arm 3.
NOTE:
Apply the molybdenum disulfide grease on the
collars and oil seal lips.

5 - 57
CHASSWINGARM
3. Install:
Collar 1
To connecting rod 2.
NOTE:
Apply the molybdenum disulfide grease on the
collar and oil seal lips.
4. Install:
Connecting rod 1
Bolt (connecting rod) 2
Plain washer 3
Nut (connecting rod) 4
To relay arm 5.
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
T R..80 Nm (8.0 m · kg, 58 ft · lb)
5. Install:
Relay arm 1
Bolt (relay arm) 2
Plain washer 3
Nut (relay arm) 4
To swingarm.
NOTE:
Apply the molybdenum disulfide grease on
the bolt.
Do not tighten the nut yet.

5 - 58
CHASSWINGARM
6. Install:
Swingarm 1
Pivot shaft 2
NOTE:
Apply the molybdenum disulfide grease on
the pivot shaft.
Insert the pivot shaft from right side.
T R..85 Nm (8.5 m · kg, 61 ft · lb)
7. Check:
Swingarm side play a
Free play exists → Replace thrust bear-
ing.
Swingarm up and down movement b
Unsmooth movement/binding/rough
spots → Grease or replace bearings,
bushes and collars.
8. Install:
Bolt (connecting rod) 1
Plain washer 2
Nut (connecting rod) 3
NOTE:
Apply the molybdenum disulfide grease on
the bolt.
Do not tighten the nut yet.
9. Install:
Bolt (rear shock absorber-relay arm) 1
Nut (rear shock absorber-relay arm) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
T R..53 Nm (5.3 m · kg, 38 ft · lb)
10. Tighten:
Nut (connecting rod) 1
T R..80 Nm (8.0 m · kg, 58 ft · lb)

5 - 59
CHAS
11. Tighten:
Nut (relay arm) 1
T R..80 Nm (8.0 m · kg, 58 ft · lb)
12. Install:
Cap 1
NOTE:
Install the cap (right) with its mark a facing
forward.
13. Install:
Bolt [chain tensioner (lower)] 1
Plain washer 2
Collar 3
Chain tensioner 4
Nut [chain tensioner (lower)] 5
T R..20 Nm (2.0 m · kg, 14 ft · lb)
14. Install:
Chain support 1
Support cover 2
Bolt {chain support [ = 50 mm (1.97 in)]}
3
Nut (chain support) 4
Bolt {support cover [ = 10 mm (0.39 in)]}
5
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
SWINGARM

5 - 61
CHASREAR SHOCK ABSORBER
Extent of removal Order Part name Q’ty Remarks
Cylinder head breather hose Disconnect at the air filter case side.
Battery Refer to “BATTERY INSPECTION AND
CHARGING” section in the CHAPTER 3.
Disconnect the starter relay cou-
pler.
Starter motor lead Disconnect at the starter relay side.
1 Locking tie 3
2 Taillight coupler 1
3 Starting circuit cut-off relay cou-
pler1
4 Plastic band 2
5 Clamp (air filter joint) 1 Only loosening.
6Rear frame 1
7 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
8 Bolt (rear shock absorber-frame) 1
21

5 - 67
CHASREAR SHOCK ABSORBER
2. Install:
Bush 1
Collar 2
Dust seal 3
NOTE:
Apply the molybdenum disulfide grease on
the bearing.
Apply the lithium soap base grease on the
bush, collars and dust seals.
Install the dust seals with their lips facing out-
ward.
3. Install:
Rear shock absorber
4. Install:
Bolt (rear shock absorber-frame) 1
Nut (rear shock absorber-frame) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
5. Install:
Bolt (rear shock absorber-relay arm) 1
Nut (rear shock absorber-relay arm) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
T R..56 Nm (5.6 m · kg, 40 ft · lb)
T R..53 Nm (5.3 m · kg, 38 ft · lb)
6. Install:
Rear frame 1
Bolt [rear frame (upper)] 2
Bolt [rear frame (lower)] 3
T R..32 Nm (3.2 m · kg, 23 ft · lb)
T R..29 Nm (2.9 m · kg, 21 ft · lb)
7. Tighten:
Screw (air filter joint) 1
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)

5 - 68
CHAS
8. Install:
Plastic band 1
Starting circuit cut-off relay coupler 2
Taillight coupler 3
Locking tie 4
REAR SHOCK ABSORBER

6 - 1
–+ELECELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1Headlight
2“ENGINE STOP”
button
3Clutch switch
4Diode
5Starter relay diode
6TPS (throttle posi-
tion sensor)
7Starter relay
8Fuse
9Starting circuit
cut-off relay0Taillight
ANeutral switch
BStarter motor
CAC magneto
DRectifier/regulator
EIgnition coil
FSpark plug
GStart switch
HMain switch
ICDI unit
JBatteryCOLOR CODE
B.......................Black
Br .....................Brown
Gy ....................Gray
L .......................Blue
O ......................Orange
R ......................Red
Sb.....................Sky blue
W......................White
Y.......................Yellow
B/L....................Black/Blue
EC612000
WIRING DIAGRAM
1 2345
678
90
A B
C DEFG
H
I
J
WR
WR
WY
R
BR/BBr
R
BR/BBr
RW
YW
L/RL/BBB
SbL/W
L/YBBB
WY
RYW
R
LY
B
YLB/L
B
B
ON
OFF
10A
BB
OFF
STARTSTART
R-BrL/W
B
BrL/W
BrL/W
L/B
-YB
YL
B
L-B
L/WSb
B/WBBB
W/RB/W
R/BGyBrL/W
ON
STOP
OB
LYSbB/L
W RBrB/W
L/BGyWR/B
B O
L/YSbL/R
R W
Y W
Y W
Y
L B
B
B
RRR/B
B Br B
B B B B
L/W
R
R
R R B
R
BrBr
L/W L/W
Br B
L/B
L/B
L/R

Br
R/B
L/B L/W
B/W
W W/RW
RO
L
Y
B/L
O

B
L
Y
B/LSbL/W∗1
Sb∗2B/W
B
L/R L/Y L/Y
B
SbSbL/W
BGy
SbBB/LYO
L
∗2
O B
L YL/W
B/L
∗1
CD
BH
5
9
G3 4
A 2I
EF
6 7
J8
1
0
∗
2
∗1
∗2: Except for USA
∗1: For USA
B/W .................. Black/White
L/B ................... Blue/Black
L/R ................... Blue/Red
L/Y ................... Blue/Yellow
L/W .................. Blue/White
R/B................... Red/Black