2006 YAMAHA WR 450F clock

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ENGCAMSHAFTS
REMOVAL POINTS
Camshaft
1. Remove:
Timing plug 1
Straight plug 2
2. Align:
“I” mark
With stationary pointer.
Checking steps:
Turn the crankshaft counterclockwise with
a wrench.
Align the “I” mark a on the rotor with the
stationary pointer b on the crankcase
cover. When the “I” mark is aligned with
the stationary pointer, the piston is at the
Top Dead Center (T.D.C.).
NOTE:
In order to be sure that the piston is at Top
Dead Center, the punch mark c on the
exhaust camshaft and the punch mark d
on the intake camshaft must align with the
cylinder head surface, as shown in the
illustration.
If there is no clearance, rotate the crank-
shaft counterclockwise one turn.
1
2
b
a
3. Loosen:
Tensioner cap bolt 1
4. Remove:
Timing chain tensioner 2
5. Remove:
Bolt (camshaft cap) 1
Camshaft caps 2
NOTE:
Remove the bolts (camshaft cap) in a criss-
cross pattern, working from the outside in.
CAUTION:
The bolts (camshaft cap) must be removed
evenly to prevent damage to the cylinder
head, camshafts or camshaft caps.
1
2
1
2

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ENGCAMSHAFTS
Decompression system
1. Check:
Decompression system
Checking steps:
Check that the decompressor cam 1
moves smoothly.
Check that the decompressor lever pin 2
projects from the camshaft.
Timing chain tensioner
1. Check:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver 1
and wind the tensioner rod up fully clock-
wise.
When releasing the screwdriver by press-
ing lightly with fingers, make sure that the
tensioner rod will come out smoothly.
If not, replace the tensioner assembly.
ASSEMBLY AND INSTALLATION
1. Install:
Exhaust camshaft 1
Intake camshaft 2
Installation steps:
Turn the crankshaft counterclockwise until
the “I” mark a on the rotor is aligned with
the stationary pointer b on the crankcase
cover.
NOTE:
Apply the molybdenum disulfide oil on the
camshafts.
Apply the engine oil on the decompression
system.

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ENGCAMSHAFTS
Fit the timing chain 3 onto both camshaft
sprockets and install the camshafts on the
cylinder head.
NOTE:
The camshafts should be installed onto the
cylinder head so that the exhaust cam
sprocket punch mark c and the intake cam
sprocket punch mark d align with the sur-
face of the cylinder head.
CAUTION:
Do not turn the crankshaft during the
camshaft installation. Damage or
improper valve timing will result.
Install the clips and camshaft caps 4.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m  kg, 7.2 ft  lb)
NOTE:
Apply the molybdenum disulfide oil on the
thread of the bolts (camshaft cap) 5.
Tighten the bolts (camshaft cap) in a criss-
cross pattern.
CAUTION:
The bolts (camshaft cap) must be tight-
ened evenly, or damage to the cylinder
head, camshaft caps, and camshaft will
result.
5
4
M
2. Install:
Timing chain tensioner
Installation steps:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver and
wind the tensioner rod up fully clockwise.

4 - 30
ENG
With the rod fully wound and the chain ten-
sioner UP mark a facing upward, install
the gasket 1 and the chain tensioner 2,
and tighten the bolt 3 to the specified
torque.
T R..
Bolt (timing chain tensioner):
10 Nm (1.0 m  kg, 7.2 ft  lb)
Release the screwdriver, check the ten-
sioner rod to come out and tighten the
gasket 4 and the cap bolt 5 to the speci-
fied torque.
T R..
Tensioner cap bolt:
7 Nm (0.7 m  kg, 5.1 ft  lb)
5
4New
3. Turn:
Crankshaft
Counterclockwise several turns
4. Check:
Rotor “I” mark
Align with the crankcase stationary
pointer.
Camshaft match marks
Align with the cylinder head surface.
Out of alignment → Adjust.
5. Install:
Timing plug 1
Straight plug 2
CAMSHAFTS

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ENGKICK AXLE AND SHIFT SHAFT
REMOVAL POINTS
EC4B3101
Kick axle assembly
1. Remove:
Kick axle assembly 1
NOTE:
Unhook the torsion spring 2 from the hole a
in the crankcase.
EC4C3101
Shift guide and shift lever assembly
1. Remove:
Bolt (shift guide)
Shift guide 1
Shift lever assembly 2
NOTE:
The shift lever assembly is disassembled at
the same time as the shift guide.
EC4N3100
Segment
1. Remove:
Bolt (segment) 1
Segment 2
NOTE:
Turn the segment counterclockwise until it
stops and loosen the bolt.
INSPECTION
EC4C4200
Kick axle and ratchet wheel
1. Check:
Ratchet wheel 1 smooth movement
Unsmooth movement → Replace.
Kick axle 2
Wear/damage → Replace.
Spring 3
Broken → Replace.
EC4C4300
Kick gear, kick idle gear and ratchet wheel
1. Inspect:
Kick gear 1
Kick idle gear 2
Ratchet wheel 3
Gear teeth a
Ratchet teeth b
Wear/damage → Replace.

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ENGKICK AXLE AND SHIFT SHAFT
3. Install:
Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
4. Install:
Kick axle assembly 1
Plain washer 2
NOTE:
Apply the molybdenum disulfide grease on
the contacting surfaces of the kick axle stop-
per a and ratchet wheel guide 3.
Apply the engine oil on the kick axle.
Slide the kick axle assembly into the crank-
case and make sure the kick axle stopper fits
into the ratchet wheel guide.
5. Hook:
Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
Kick idle gear
1. Install:
Kick idle gear 1
Plain washer 2
Circlip 3
NOTE:
Install the kick idle gear with its depressed
side a toward you.
Apply the engine oil on the kick idle gear
inner circumference.
New

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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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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 rangeCompression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil level (oil amount) Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Spring Replace with soft spring.
Unsmooth movement
over entire rangeOuter tube
Check for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Inner tube
Under bracket tightening
torqueRetighten to specified torque.
Poor initial
movementRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil seal Apply grease in oil seal wall.
Soft over entire
range, bottoming outCompression damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Oil level (oil amount) Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Spring Replace with stiff spring.
Stiff toward stroke
endOil level (oil amount) Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke
end, bottoming outOil 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 postureCompression damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in)
when one passenger is astride seat (lower rear pos-
ture).
Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).
“Obtrusive” front,
tending to upper front
postureCompression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in)
when one passenger is astride seat (upper rear pos-
ture).
Spring Replace with soft spring.
Oil lever (oil amount) Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).