2006 YAMAHA WR 450F Notices Demploi (in French)

SPEC
2 - 8 Clutch:
Friction plate thickness 2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)2.8 mm
(0.110 in)
Quantity 8 ----
Clutch plate 1 thickness 1.9 ~ 2.1 mm (0.075 ~ 0.083 in) ----
Quantity 4 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch plate 2 thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) ----
Quantity 3 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch spring free length 50.0 mm (1.97 in) 49.0 mm
(1.93 in)
Quantity 6 ----
Clutch housing thrust clearance 0.10 ~ 0.35 mm
(0.0039 ~ 0.0138 in)----
Clutch housing radial clearance 0.010 ~ 0.044 mm
(0.0004 ~ 0.0017 in)----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm
(0.002 in)
Kickstarter:
Type Ratchet type ----
Carburetor:
I. D. mark 5TJ8 80 ----
Main jet (M.J) #165 ----
Main air jet (M.A.J)ø2.0 ----
Jet needle (J.N) NFNT ----
Cutaway (C.A) 1.5 ----
Pilot jet (P.J) #45 ----
Pilot air jet (P.A.J) #80 ----
Pilot outlet (P.O)ø0.9 ----
Bypass (B.P)ø1.0 ----
Valve seat size (V.S)ø3.8 ----
Starter jet (G.S) #65 ----
Leak jet (Acc.P) #50 ----
Float height (F.H) 8 mm (0.31 in) ----
Engine idle speed 1,700 ~ 1,900 r/min ----
Intake vacuum 34.3 ~ 40.7 kPa
(260 ~ 300 mmHg,
10.24 ~ 11.81 inHg)----
Hot starter lever free play 3 ~ 6 mm (0.12 ~ 0.24 in) ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 9 Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance “A”0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Tip clearance “B”0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Side clearance “C”0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.007 in)
Bypass valve setting pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm
2,
5.69 ~ 11.38 psi)----
Cooling:
Radiator core size
Width 117.8 mm (4.6 in) ----
Height 260 mm (10.2 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.71 L (0.62 Imp qt, 0.75 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 10 Item Standard
Lubrication chart:
Pressure feed
Splashed scavenge
Oil strainer
Oil pan Oil pump rotor 2
Oil pump rotor 1
Oil tank
Oil filter
Check ball
Cylinder head
Crank pinPiston pinPiston
Drive axleMain axleTransmission gears
Camshaft
Valve lifter
MAINTENANCE SPECIFICATIONS

SPEC
2 - 11 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
M8 × 1.25 1 15 1.5 11
(bolt) M10 × 1.25 4 Refer to NOTE.*
1
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Timing chain guide (rear) M6 × 1.0 2 10 1.0 7.2
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 16 1.6 11
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
Spark arrester M5 × 0.8 4 7 0.7 5.1
Silencer cap M5 × 0.8 6 5 0.5 3.6
Carburetor joint clamp (cylinder head side) M5 × 0.8 1 3 0.3 2.2
Carburetor joint clamp (carburetor side) M4 × 0.7 1 3 0.3 2.2
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Radiator panel (upper) M6 × 1.0 2 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Radiator pipe 1, 2 M10 × 1.0 2 10 1.0 7.2
Impeller M8 × 1.25 1 14 1.4 10
Water pump housing cover M6 × 1.0 3 10 1.0 7.2
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 9 0.9 6.5
Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2
Oil filter cover M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 M10 × 1.25 1 20 2.0 14
M8 × 1.25 2 18 1.8 13
Oil delivery pipe 2 M6 × 1.0 1 10 1.0 7.2
Oil hose M6 × 1.0 2 8 0.8 5.8
MAINTENANCE SPECIFICATIONS

SPEC
2 - 12
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.
NOTE:
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m  kg, 22 ft  lb) in the proper tightening sequence,
remove and retighten the cylinder head bolts to 20 Nm (2.0 m  kg, 14 ft  lb) in the proper tightening
sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the
proper tightening sequence.Oil check bolt M6 × 1.0 1 10 1.0 7.2
Oil hose clamp—220.21.4
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase cover (right) M6 × 1.0 10 10 1.0 7.2
Crankcase cover (left) M6 × 1.0 9 10 1.0 7.2
Idle gear cover (starter motor) M6 × 1.0 2 10 1.0 7.2
Crankcase M6 × 1.0 12 12 1.2 8.7
Clutch cable holder M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (crankcase rear) M10 × 1.25 1 20 2.0 14
(crankcase left) M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (frame) M8 × 1.25 1 23 2.3 17
Oil strainer (frame) M14 × 1.5 1 70 7.0 50
Crankcase bearing stopper M6 × 1.0 15 10 1.0 7.2
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter M8 × 1.25 1 33 3.3 24
Screw (kickstarter) M6 × 1.0 1 7 0.7 5.1
Starter clutch M6 × 1.0 6 16 1.6 11
Primary drive gear M20 × 1.0 1 110 11.0 80
Clutch boss M20 × 1.0 1 75 7.5 54
Push lever M6 × 1.0 1 10 1.0 7.2
Clutch spring M6 × 1.0 6 8 0.8 5.8
Balancer driven gear M14 × 1.0 1 50 5.0 36
Balancer weight plate M6 × 1.0 3 10 1.0 7.2
Drive sprocket M20 × 1.0 1 75 7.5 54
Drive sprocket cover M6 × 1.0 2 8 0.8 5.8
Shift pedal M6 × 1.0 1 12 1.2 8.7
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
MAINTENANCE SPECIFICATIONS

SPEC
2 - 13
EC212201
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN EUROPE AUS, NZ, ZA
Front fork travel 300 mm (11.8 in)← ←
Fork spring free length 460 mm (18.1 in)← ←
Spring rate, STD K = 4.5 N/mm
(0.459 kg/mm,
25.7 lb/in)K = 4.2 N/mm
(0.428 kg/mm,
24.0 lb/in)K = 4.4 N/mm
(0.449 kg/mm,
25.1 lb/in)
Optional spring/spacer Yes← ←
Oil capacity 650 cm
3
(22.9 Imp oz,
22.0 US oz) 653 cm3
(23.0 Imp oz,
22.1 US oz) 655 cm3
(23.1 Imp oz,
22.1 US oz)
Oil level 130 mm (5.12 in) 127 mm (5.00 in) 125 mm (4.92 in)

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)95 ~ 150 mm
(3.74 ~ 5.91 in)← ←
Oil grade Suspension oil
“S1”← ←
Inner tube outer diameter 48 mm (1.89 in)← ←
Front fork top end Zero mm (Zero in)← ←
Rear suspension: USA, CDN EUROPE AUS, NZ, ZA
Shock absorber travel 129 mm (5.08 in)← ←
Spring free length260 mm (10.24 in)← ←
Fitting length 247 mm (9.72 in) 246 mm (9.69 in) 247 mm (9.72 in)
237.5 ~ 258.5 mm
(9.35 ~ 10.18 in)← ←
Spring rate, STD K = 52.0 N/mm
(5.30 kg/mm,
296.8 lb/in)K = 48.0 N/mm
(4.90 kg/mm,
274.4 lb/in)K = 54.0 N/mm
(5.50 kg/mm,
308.0 lb/in)
Optional spring Yes← ←
Enclosed gas pressure
1,000 kPa
(10 kg/cm2, 142 psi)
← ←
Swingarm:
Swingarm free play limit
End ---- 1.0 mm
(0.04 in)
MAINTENANCE SPECIFICATIONS

SPEC
2 - 14 Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 21 × 1.60/Aluminum ----
Rear rim size/material 18 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm
(0.08 in)
Lateral ---- 2.0 mm
(0.08 in)
Drive chain:
Type/manufacturer DID520VM/DAIDO ----
Number of links 113 links + joint ----
Chain slack 48 ~ 58 mm (1.9 ~ 2.3 in) ----
Chain length (15 links) ---- 239.3 mm
(9.42 in)
Front disc brake:
Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in)
250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in)
245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)5 mm (0.20 in) ----
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 15
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m  kg, 27 ft  lb) by using the ring nut
wrench, then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m  kg, 5.1 ft  lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Handle crown and outer tube M8 × 1.25 4 23 2.3 17
Under bracket and outer tube M8 × 1.25 4 20 2.0 14
Handle crown and steering shaft M24 × 1.0 1 145 14.5 105
Handlebar holder (upper) M8 × 1.25 4 28 2.8 20
Handlebar holder (lower) M12 × 1.25 2 40 4.0 29
Steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M51 × 1.5 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21
Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and protector M6 × 1.0 6 7 0.7 5.1
Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1
Throttle cable cap M5 × 0.8 2 4 0.4 2.9
Clutch lever holder mounting M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting M6 × 1.0 1 4 0.4 2.9
Hot starter lever holder mounting M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting M5 × 0.8 1 2 0.2 1.4
Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3
Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Hose guide (front brake hose) and hose guide bracketM5 × 0.8 1 4 0.4 2.9
Hose guide (front brake hose) and under bracketM6 × 1.0 1 4 0.4 2.9
Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Front brake caliper and front fork M8 × 1.25 2 23 2.3 17
Front brake caliper and brake hose holder M6 × 1.0 1 10 1.0 7.2
Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2
Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13
Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3
Front wheel axle and nut M16 × 1.5 1 90 9.0 65
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
Brake pedal mounting M8 × 1.25 1 26 2.6 19
Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
MAINTENANCE SPECIFICATIONS