2007 YAMAHA WR 450F clutch

4 - 56
ENGCLUTCH
EC4A5000
ASSEMBLY AND INSTALLATION
Push lever
1. Install:
Push lever 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Apply the engine oil on the push lever.
Clutch
1. Install:
Primary driven gear 1
Thrust washer 2
Clutch boss 3
NOTE:
Apply the engine oil on the primary driven gear
inner circumference.
2. Install:
Lock washer 1
Nut (clutch boss) 2
NOTE:
Install the lock washer with its concaves fit-
ted over the convexes of the clutch boss.
Use the clutch holding tool 3 to hold the
clutch boss.
ÈFor USA and CDN
ÉExcept for USA and CDN
Clutch holding tool:
YM-91042/90890-04086
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)
ÈÉ

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ENGCLUTCH
3. Bend the lock washer 1 tab.
4. Install:
Friction plate 1
Clutch plate 1
[t = 2.0 mm (0.079 in)] 2
Clutch plate 2
[t = 1.6 mm (0.063 in)] 3
NOTE:
Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
Apply the engine oil on the friction plates and
clutch plates.
Check the clutch plate for thickness and
install 4 thicker ones a on the engine side
and 3 thinner ones b on the outside.
ab
5. Install:
Bearing 1
Plain washer 2
Circlip 3
To push rod 1 4.
NOTE:
Apply the engine oil on the bearing and plain
washer.
New
6. Install:
Push rod 2 1
Ball 2
Push rod 1 3
NOTE:
Apply the engine oil on the push rod 1, 2 and
ball.

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ENGCLUTCH
7. Install:
Pressure plate 1
8. Install:
Clutch spring
Bolt (clutch spring)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
9. Install:
Gasket (clutch cover) 1
Dowel pin 2
New
10. Install:
Clutch cover 1
Bolt (clutch cover)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)
Extent of removal:
1 Oil filter removal
2 Water pump removal
3 Crankcase cover (right) removal
Extent of removal Order Part name Q’ty Remarks
OIL FILTER, WATER PUMP
AND CRANKCASE COVER
(RIGHT) REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cover Refer to “CLUTCH” section.
1 Oil filter cover 1
2 Oil filter 1
3 Coolant pipe 2 1
4 Water pump housing 1
5Pin 2
6 Oil tank breather hose 1
1
2
3

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ENGBALANCER
BALANCER
BALANCER
Extent of removal:
1 Balancer drive gear
2 Balancer
Extent of removal Order Part name Q’ty Remarks
BALANCER REMOVAL
Preparation for removal Clutch housing Refer to “CLUTCH” section.
Crankcase cover (right) Refer to “OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT)”
section.
Stator Refer to “AC MAGNETO AND
STARTER CLUTCH” section.
1 Nut (balancer) 1
Refer to “REMOVAL POINTS”. 2 Nut (primary drive gear) 1
3 Nut (balancer driven gear) 1
4 Lock washer 1
5 Balancer 1
6 Straight key 1
2
1
2

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ENGOIL PUMP
OIL PUMP
OIL PUMP
Extent of removal:
1 Oil pump removal
2 Oil pump disassembly
Extent of removal Order Part name Q’ty Remarks
OIL PUMP REMOVAL AND DIS-
ASSEMBLY
Preparation for removal Clutch housing Refer to “CLUTCH” section.
Crankcase cover (right) Refer to “OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT)”
section.
1 Circlip 1
2 Plain washer 1
3 Oil pump drive gear 1
4 Oil pump assembly 1
5 Dowel pin 2
6 Outer rotor 2 1
7 Circlip 1
8 Inner rotor 2 1
9Pin 1
10 Oil pump cover 1
11 Outer rotor 1 1
12 Inner rotor 1 1
1
2

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ENGKICK AXLE AND SHIFT SHAFT
3. Install:
Shift lever assembly 1
Shift guide 2
NOTE:
The shift lever assembly is installed at the
same time as the shift guide.
Apply the engine oil on the bolt (segment)
shaft.
4. Install:
Bolt (shift guide) 1
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
EC4C5301
Shift shaft
1. Install:
Roller 1
Collar 2
Torsion spring 3
Plain washer 4
Shift shaft 5
NOTE:
Apply the engine oil on the roller and shift
shaft.
2. Install:
Shift pedal
Refer to “AC MAGNETO AND STARTER
CLUTCH” section.

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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.
Disconnect the AC magneto lead.
1 Shift pedal 1
2 Cover (torque limiter) 1
3 Torque limiter 1 Do not disassemble.
4 Crankcase cover (left) 1
5 Gasket 1
6 Dowel pin 2
13