2007 YAMAHA WR 450F oil

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ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
3. Install:
O-ring
Coolant pipe 1
Bolt (coolant pipe) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Oil filter
1. Install:
Oil filter 1
O-ring 2
Oil filter cover 3
Bolt (oil filter cover)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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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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ENGBALANCER
ASSEMBLY AND INSTALLATION
Balancer, balancer drive gear and balancer
driven gear
1. Install:
Balancer driven gear 1
NOTE:
Install the balancer driven gear and balancer
shaft with their lower splines a aligning with
each other.
2. Install:
Balancer drive gear 1
NOTE:
Align the punched mark a on the balancer
drive gear with the punched mark b on the
balancer driven gear.
Install the balancer driven gear and crank-
shaft with the lower splines c aligning with
each other.
3. Install:
Lock washer 1
Nut (balancer driven gear) 2
Primary drive gear 3
Conical washer 4
Nut (primary drive gear) 5
Straight key 6
Balancer 7
Lock washer 8
Nut (balancer) 9
NOTE:
Apply engine oil to the contact surface and
threaded portion of the nut (primary drive
gear).
Place an aluminum plate a between the
teeth of the balancer drive gear 0 and bal-
ancer driven gear A.
Install the conical washer with its convex sur-
face b outward.
4. Bend the lock washer tab.
a 0
1A
2
T R..50 Nm (5.0 m · kg, 36 ft · lb)
T R..110 Nm (11.0 m · kg, 80 ft · lb)
T R..45 Nm (4.5 m · kg, 33 ft · lb)

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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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ENGOIL PUMP
Extent of removal Order Part name Q’ty Remarks
13 Pin 1
14 Washer 1
15 Oil pump drive shaft 1
16 Rotor housing 1
2

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ENGOIL PUMP
INSPECTION
Oil pump
1. Inspect:
Oil pump drive gear
Oil pump driven gear
Rotor housing
Oil pump cover
Cracks/wear/damage → Replace.
2. Measure:
Tip clearance a
Between the inner rotor 1 and the outer
rotor 2.
Tip clearance b
Between the outer rotor 2 and the rotor
housing 3.
Out of specification → Replace the oil
pump.
3. Check:
Unsmooth → Repeat steps #1 and #2 or
replace the defective parts.
ASSEMBLY AND INSTALLATION
Oil pump
1. Install:
Oil pump drive shaft 1
Washer 2
Pin 3
Inner rotor 1 4
NOTE:
Apply the engine oil on the oil pump drive
shaft and inner rotor 1.
Fit the pin into the groove in the inner rotor 1.
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)

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ENGOIL PUMP
2. Install:
Outer rotor 1 1
NOTE:
Apply the engine oil on the outer rotor 1.
3. Install:
Oil pump cover 1
Screw (oil pump cover) 2
Pin 3
Inner rotor 2 4
Circlip 5
NOTE:
Apply the engine oil on the oil pump drive
shaft end and inner rotor 2.
Fit the pin into the groove in the inner rotor 2.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
New
4. Install:
Outer rotor 2 1
Dowel pin 2
Oil pump assembly 3
Bolt (oil pump assembly) 4
NOTE:
Apply the engine oil on the outer rotor 2.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
5. Install:
Oil pump drive gear 1
Plain washer 2
Circlip 3
NOTE:
Apply the engine oil on the oil pump drive gear
inner circumference.
New

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ENGKICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
Extent of removal:
1 Kick axle removal
2 Kick axle disassembly
3 Shift shaft removal
4 Segment removal
Extent of removal Order Part name Q’ty Remarks
KICK AXLE AND SHIFT SHAFT
REMOVAL
Preparation for removal Oil pump Refer to “OIL PUMP” section.
1 Kick idle gear 1
2 Kick axle assembly 1 Refer to “REMOVAL POINTS”.
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick axle 1
8 Plain washer 1
9 Shift pedal 1
10 Shift shaft 1
11 Collar 1
12 Torsion spring 1
1
1
2
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