2005 YAMAHA WR 450F clutch

4 - 100
ENGCRANKCASE AND CRANKSHAFT
5. Install:
Dowel pin 1
O-ring 2
Crankcase (right)
To crankcase (left).
NOTE:
Fit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft ham-
mer.
When installing the crankcase, the connect-
ing rod should be positioned at TDC (top
dead center).
New
6. Tighten:
Hose guide 1
Clutch cable holder 2
Bolt (clutch cable holder)
Bolt (crankcase)
NOTE:
Tighten the crankcase tightening bolts in
stage, using a crisscross pattern.
7. Install:
Oil delivery pipe
O-ring
Bolt (oil delivery pipe 2)
8. Install:
Timing chain
Timing chain guide (rear)
Bolt (timing chain guide)
9. Remove:
Sealant
Forced out on the cylinder mating surface.
10. Apply:
Engine oil
To the crank pin, bearing and oil delivery
hole.
11. Check:
Crankshaft and transmission operation.
Unsmooth operation → Repair.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

5 - 39
CHAS
EC5B0000
HANDLEBAR
Extent of removal:
1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
HANDLEBAR REMOVAL
Preparation for removal Headlight
1 Hot starter cable 1 Disconnect at the lever side.
2 Hot starter lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1 Disconnect the clutch switch lead.
5“ENGINE STOP” button 1 Disconnect the “ENGINE STOP” button
lead.
6 Master cylinder 1 Refer to “REMOVAL POINTS”.
7 Start switch 1 Disconnect the start switch lead.
8 Throttle cable cap 1
9 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
10 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
11 Grip (right) 1 Refer to “REMOVAL POINTS”.
12 Tube guide 1
13 Cover (grip cap) 1
14 Grip (left) 1 Refer to “REMOVAL POINTS”.
15 Handlebar holder (upper) 2
16 Handlebar 1
1
HANDLEBAR

5 - 44
CHASHANDLEBAR
9. Install:
“ENGINE STOP” button 1
Clutch lever holder 2
Bolt (clutch lever holder) 3
Hot starter lever holder 4
Bolt (hot starter lever holder) 5
Clamp 6
NOTE:
The “ENGINE STOP” button, clutch lever
holder and clamp should be installed accord-
ing to the dimensions shown.
Pass the “ENGINE STOP” button lead in the
middle of the clutch lever holder.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
10. Install:
Clutch cable 1
Hot starter cable 2
NOTE:
Apply the lithium soap base grease on the
clutch cable end and hot starter cable end.
11. Adjust:
Clutch lever free play
Refer to “CLUTCH ADJUSTMENT” sec-
tion in the CHAPTER 3.
Hot starter lever free play
Refer to “HOT STARTER LEVER
ADJUSTMENT” section in the CHAPTER
3.
12. Fasten the hot starter cable 1 and clutch
cable 2 with a clamp 3.
1
2
3

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

6 - 7
–+ELEC
ELECTRIC STARTING SYSTEM
STARTING CIRCUIT CUT-OFF SYSTEM
OPERATION
If the main switch is set to “ON”, the starter
motor can only operate if at least one of the fol-
lowing conditions is met:
The transmission is in neutral (the neutral
switch is closed).
The clutch lever is pulled to the handlebar
(the clutch switch is closed).
The starting circuit cut-off relay prevents the
starter motor from operating when neither of
these conditions has been met. In this
instance, the starting circuit cut-off relay is
open so current cannot reach the starter
motor. When at least one of the above condi-
tions has been met the starting circuit cut-off
relay is closed and the engine can be started
by pressing the start switch.
WHEN THE TRANSMISSION IS
IN NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR
1Battery
2Main fuse
3Main switch
4Starting circuit cut-off relay
5Start switch
6Diode
7Clutch switch
8Neutral switch
9Starter relay
0Starter motor
12
M
3
4
5
8 76 9
0
ELECTRIC STARTING SYSTEM

–+ELEC
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.
*1 Check fuse.Replace 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 goodNo good
No good
No good
Pocket tester:
YU-3112-C/90890-03112

6 - 10
–+ELECELECTRIC STARTING SYSTEM
STARTER RELAY INSPECTION
1. Remove:
Starter relay
2. Inspect:
Starter relay conduct
Use 12 V battery.
Continuous while not connected to the battery
→ Replace.
Not continuous while connected to the battery
→ Replace. Battery (+) lead
→
Starter relay terminal
1
Battery (–) lead
→
Starter relay terminal
2
Tester (+) lead
→ Starter relay terminal
3
Tester (–) lead
→ Starter relay terminal
4
Ter-
minal
3
Ter-
minal

4 Tester selec-
tor position
Con-
nected to
battery
Ω
× 1
Not con-
nected to
battery
CLUTCH SWITCH INSPECTION
1. Inspect:
Clutch switch continuity
No continuous while being pulled → Replace.
Continuous while being freed → Replace. Tester (+) lead
→ Black lead
1
Tester (–) lead
→ Black lead
2
B
1 B
2 Tester selec-
tor position
PULL
Ω
× 1
FREE

6 - 12
–+ELECELECTRIC STARTING SYSTEM
STARTER MOTOR
0
9
56
7
5 0 8
9
4
3
2
1
New
New
New
B
5
1
Extent of removal:
1 Starter motor disassembly
Extent of removal Order Part name Q’ty Remarks
STARTER MOTOR REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Crankcase cover (left) Refer to “AC MAGNETO AND
STARTER CLUTCH” section in the
CHAPTER 4.
1 Starter motor 1
STARTER MOTOR DISASSEM-
BLY
1 Starter motor front cover 1
2 Washer (starter motor front
cover)1
3 Plain washer 1
4 Circlip 1
5 O-ring 3
1