2006 YAMAHA WR 450F oil

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ENGAC MAGNETO AND STARTER CLUTCH
AC MAGNETO AND STARTER CLUTCH
Extent of removal:
1 Starter clutch/wheel gear removal
2 Rotor removal
3 Pickup coil/stator removal
Extent of removal Order Part name Q’ty Remarks
AC MAGNETO AND STATOR
REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Bolt [radiator (left)]
Disconnect the AC magneto lead.Refer to “RADIATOR” section.
1 Shift pedal 1
2 Engine guard (left) 1
3 Cover (torque limiter) 1
4 Torque limiter 1 Do not disassemble.
5 Crankcase cover (left) 1
6 Gasket 1
13

4 - 80
ENGAC MAGNETO AND STARTER CLUTCH
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).
Extent of removal Order Part name Q’ty Remarks
7 Dowel pin 2
8 Idle gear 1
9 Bearing 1
10 Shaft 1
11* Nut (rotor) 1 Refer to NOTE.
12 Rotor 1 Use special tool.
Refer to “REMOVAL POINTS”.
13 Woodruff key 1
14 Starter clutch 1
15 Starter clutch drive gear 1
16 Holder 1
17 Pick-up coil 1
18 Stator 1
3
3
2
1

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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 É, 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 È, 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)

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ENGAC MAGNETO AND STARTER CLUTCH
2. Install:
Holder 1
Bolt 2
NOTE:
Pass the pick-up coil lead 3 and AC mag-
neto lead 4 under the holder as shown.
Take care not to catch the AC magneto lead
between crankcase cover ribs.
Apply the sealant to the grommet of the AC
magneto lead.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No. 1215:
90890-85505
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
Starter clutch drive gear 1
Starter clutch 2
NOTE:
Apply the engine oil on the starter clutch drive
gear inner circumference.
4. Install:
Woodruff key 1
Rotor 2
NOTE:
Clean the tapered portions of the crankshaft
and rotor.
When installing the woodruff key, make sure
that its flat surface a is in parallel with the
crankshaft center line b.
When installing the rotor, align the keyway c
of the rotor with the woodruff key.
c
2 1 1
ba

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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 ftlb), 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

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ENGENGINE REMOVAL
EC4M0000
ENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is nodanger of it falling over.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM”
section.
Clutch cable and guide Disconnect at the engine side.
Radiator Refer to “RADIATOR” section.
Shift pedal Refer to “AC MAGNETO AND
STARTER CLUTCH” section.
Cylinder head breather hose and
oil tank breather hoseRefer to “CAMSHAFTS” section.

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ENGENGINE REMOVAL
Extent of removal:
1 Engine removal
Extent of removal Order Part name Q’ty Remarks
Ignition coil
Disconnect the AC magneto lead.
Crankcase cover (left) Refer to “AC MAGNETO AND
STARTER CLUTCH” section for remov-
ing the starter motor lead.
Disconnect the starter motor
lead.Refer to “ELECTRIC STARTING SYS-
TEM” section in the CHAPTER 6.
Negative battery lead Disconnect at the starter motor side.
1 Engine skid plate (front) 1
2 Neutral switch 1
3 Oil hose 2
4 Chain cover 1
5 Nut (drive sprocket) 1
Refer to “REMOVAL POINTS”. 6 Lock washer 1
7 Drive sprocket 1
8Clip 1
9 Bolt (brake pedal) 1
10 Brake pedal 1
1

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ENGENGINE REMOVAL
Drive sprocket
1. Install:
Drive sprocket 1
Drive chain 2
NOTE:
Install the drive sprocket together with the
drive chain.
2. Install:
Lock washer 1
Nut (drive sprocket) 2
NOTE:
Tighten the nut while applying the rear brake.
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)
3. Bend the lock washer tab to lock the nut.
4. Install:
Chain guide
Chain cover 1
Screw (chain cover) 2
5. Install:
O-ring 1
Dowel pin 2
Oil hose 3
Bolt (oil hose) 4
NOTE:
Apply the lithium soap base grease on the O-
ring.
6. Install:
Spring 1
Pin 2
O-ring 3
Neutral switch 4
Screw (neutral switch) 5
NOTE:
Apply the lithium soap base grease on the O-
ring.
21T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
New
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
New
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)