2006 YAMAHA WR 450F transmission oil

4 - 94
ENGCRANKCASE AND CRANKSHAFT
CRANKCASE BEARING
Extent of removal:
1 Crankcase bearing removal
Extent of removal Order Part name Q’ty Remarks
CRANKCASE BEARING
REMOVAL
Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT
CAM AND SHIFT FORK” section.
Shift cam and shift fork
1 Oil seal 3
2 Bearing 10 Refer to “REMOVAL POINTS”.
1

4 - 99
ENGCRANKCASE AND CRANKSHAFT
NOTE:
Hold the connecting rod at top dead center
with one hand while turning the nut of the
installing tool with the other. Operate the
installing tool until the crankshaft bottoms
against the bearing.
Before installing the crankshaft, clean the
contacting surface of crankcase.
CAUTION:
Do not use a hammer to drive in the crank-
shaft.
2. Check:
Shifter operation
Transmission operation
Unsmooth operation → Repair.
3. Install:
Oil strainer 1
Bolt (oil strainer) 2
4. Apply:
Sealant
On the crankcase (right) 1.
NOTE:
Clean the contacting surface of crankcase (left
and right) before applying the sealant.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No. 1215:
90890-85505
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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)

4 - 103
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H4801
Shift fork, shift cam and segment
1. Inspect:
Shift fork 1
Wear/damage/scratches → Replace.
2. Inspect:
Shift cam 1
Segment 2
Bend/wear/damage → Replace.
3. Check:
Shift fork movement
Unsmooth operation → Replace shift
fork.
NOTE:
For a malfunctioning shift fork, replace not only
the shift fork itself but the two gears each adja-
cent to the shift fork.
ASSEMBLY AND INSTALLATION
Transmission
1. Install:
5th pinion gear (25T) 1
3rd pinion gear (16T) 2
Collar 3
4th pinion gear (20T) 4
2nd pinion gear (15T) 5
To main axle 6.
NOTE:
Apply the molybdenum disulfide oil on the
inner and end surface of the idler gear and on
the inner surface of the sliding gear, then
install.

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ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
2. Install:
2nd wheel gear (26T) 1
4th wheel gear (21T) 2
3rd wheel gear (21T) 3
5th wheel gear (21T) 4
1st wheel gear (29T) 5
O-ring 6
To drive axle 7.
NOTE:
Apply the molybdenum disulfide oil on the
inner and end surface of the idler gear and
on the inner surface of the sliding gear, then
install.
Apply the lithium soap base grease on the O-
ring.
3. Install:
Plain washer 1
Circlip 2
NOTE:
Be sure the circlip sharp-edged corner a is
positioned opposite side to the plain washer
and gear b.
Install the circlip with its ends c settled
evenly on the spline crests.
cc
New
4. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
When installing the spacer into the crank-
case, pay careful attention to the crankcase
oil seal lip.

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ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
5. Install:
Shift fork 1 (L) 1
Shift fork 2 (C) 2
Shift fork 3 (R) 3
Shift cam 4
To main axle and drive axle.
NOTE:
Apply the molybdenum disulfide oil on the
shift fork grooves.
Mesh the shift fork #1 (L) with the 4th wheel
gear 5 and #3 (R) with the 5th wheel gear 7
on the drive axle.
Mesh the shift fork #2 (C) with the 3rd pinion
gear 6 on the main axle.
6. Install:
Transmission assembly 1
To crankcase (left) 2.
NOTE:
Apply the engine oil on the bearings and guide
bars.
7. Check:
Shifter operation
Transmission operation
Unsmooth operation → Repair.

5 - 3
CHAS
DEMONTAGE-EINZELHEITEN
Hinterrad
1. Demontieren:
Rad
1
HINWEIS:
Das Hinterrad nach vorn drücken
und die Antriebskette
2 abnehmen.
Radlager (nach Bedarf)
1. Demontieren:
Lager
1
HINWEIS:
Das Lager mit einem Lageraustreiber
2 ausbauen.
KONTROLLE
Rad
1. Messen:
Felgenschlag
Nicht nach Vorgabe
→ Instand
setzen/erneuern.
Max. Felgenschlag:
Höhenschlag 1:
2,0 mm (0,08 in)
Seitenschlag 2:
2,0 mm (0,08 in)
2. Kontrollieren:
Lager
Den Innenlaufring mit den Fin-
gern drehen.
Stockend/fest
→ Erneuern.
HINWEIS:
Lager, Dichtring und Distanzhülse
satzweise erneuern. POINTS DE DEPOSE
Roue arrière
1. Déposer:
Roue 1
N.B.:
Pousser la roue vers l’avant et déposer la
chaîne de transmission 2.
Roulement de roue (si nécessaire)
1. Déposer:
Roulement 1
N.B.:
Déposer le roulement à l’aide d’un arra-
che-roulement courant 2.
CONTROLE
Roue
1. Mesurer:
Voile de roue
Hors spécifications → Réparer/
remplacer.
Limite de voile de roue:
Radial 1:
2,0 mm (0,08 in)
Latéral 2:
2,0 mm (0,08 in)
2. Contrôler:
Roulement
Faire tourner la cage interne avec
le doigt.
Rugosité/grippage → Remplacer.
N.B.:
Remplacer ensemble les roulements, la
bague d’étanchéité et l’entretoise épau-
lée de roue.PUNTOS DE DESMONTAJE
Rueda trasera
1. Extraer:
Rueda 1
NOTA:
Empuje la rueda hacia adelante y des-
monte la cadena de transmisión 2.
Cojinete de rueda (si es necesario)
1. Extraer:
Cojinete 1
NOTA:
Extraiga el cojinete con un extractor
general de cojinetes 2.
COMPROBACIÓN
Rueda
1. Medir:
Descentramiento de la rueda
Fuera de límite → Reparar/cam-
biar.
Límite de descentramiento
de la rueda:
Radial 1:
2,0 mm (0,08 in)
Lateral 2:
2,0 mm (0,08 in)
2. Comprobar:
Cojinete
Gire la guía interior con un dedo.
Punto duro/agarrotamiento →
Cambiar.
NOTA:
Cambie el conjunto de cojinetes, junta de
aceite y manguito de la rueda.
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
RUEDA DELANTERA Y RUEDA TRASERA