2007 YAMAHA WR 450F fuel tank removal

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS ..................................4-1
EXHAUST PIPE AND SILENCER .............4-3
RADIATOR ................................................4-5
CARBURETOR ..........................................4-8
AIR INDUCTION SYSTEM ......................4-22
CAMSHAFTS ...........................................4-24
CYLINDER HEAD ....................................4-33
VALVES AND VALVE SPRINGS ............4-37
CYLINDER AND PISTON ........................4-46
CLUTCH ...................................................4-52
OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT) .....4-59
BALANCER .............................................4-66
OIL PUMP ................................................4-70
KICK AXLE AND SHIFT SHAFT .............4-74
AC MAGNETO
AND STARTER CLUTCH ........................4-82
ENGINE REMOVAL .................................4-89
CRANKCASE AND CRANKSHAFT ........4-95
TRANSMISSION, SHIFT CAM
AND SHIFT FORK .................................4-104
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL .......5-1
FRONT BRAKE AND REAR BRAKE .....5-10
FRONT FORK ..........................................5-26
HANDLEBAR ...........................................5-39
STEERING ...............................................5-46
SWINGARM .............................................5-52
REAR SHOCK ABSORBER ....................5-60

4 - 1
ENG
EC400000
ENGINE
EC4R0000
SEAT, FUEL TANK AND SIDE COVERS
Extent of removal:
1 Seat removal
2 Fuel tank removal
3 Side covers removal
4 Headlight removal
Extent of removal Order Part name Q’ty Remarks
SEAT, FUEL TANK AND SIDE
COVERS REMOVAL
Preparation for removal Turn the fuel cock to “OFF”.
Disconnect the fuel hose.
1Seat 1
2 Air scoop (left and right) 2
3 Bolt (fuel tank) 2
4 Fuel tank 1
5 Side cover (left) 1 Open the air filter case cover.
6 Side cover (right) 1 Refer to “REMOVAL POINTS”.
7 Headlight coupler 1
8 Headlight 1
31
2
3
4
SEAT, FUEL TANK AND SIDE COVERS

4 - 2
ENG
REMOVAL POINTS
Side cover
1. Remove:
• Bolt (side cover)
 Side cover (right) 1
NOTE:
Draw the side cover backward to remove it
because its claw a is inserted in the air filter
case.
SEAT, FUEL TANK AND SIDE COVERS

4 - 3
ENGEXHAUST PIPE AND SILENCER
EC4S0000
EXHAUST PIPE AND SILENCER
Extent of removal:
1 Silencer removal
2 Exhaust pipe removal
Extent of removal Order Part name Q’ty Remarks
EXHAUST PIPE AND
SILENCER REMOVAL
Preparation for removal Side cover (right) Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Bolt (clamp) 1 Only loosening.
2 Bolt [silencer (front)] 1
3 Bolt [silencer (rear)] 1
4 Collar 1
5 Silencer 1
6Clamp 1
7 Nut (exhaust pipe) 1
8 Bolt (exhaust pipe) 1
9 Exhaust pipe 1
10 Gasket 2
1
2
2

4 - 5
ENGRADIATOR
EC450001
RADIATOR
Extent of removal:
1 Radiator removal
2 Coolant reservoir removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat, fuel tank and side cover Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
1 Panel 2
2Clamp 8
3 Radiator (right) 1
4 Hose 2 1
5 Hose 3 1
6 Hose 4 1
7 Pipe 2/O-ring 1/1
8 Catch tank hose 1
9 Radiator (left) 1
10 Hose 1 1
11 Pipe 1/O-ring 1/1
12 Catch tank breather hose 1
13 Catch tank 1
1
2

4 - 8
ENGCARBURETOR
CARBURETOR
Extent of removal:
1 Carburetor removal
Extent of removal Order Part name Q’ty Remarks
CARBURETOR REMOVAL
Preparation for removal Fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Rear shock absorber Refer to “REAR SHOCK ABSORBER”
section in the CHAPTER 5.
1Clamp 2
2 TPS coupler 1
3 Throttle cable cover 1
4 Throttle cable 2
5 Clamp (air cleaner joint) 1 Loosen the screw (air cleaner joint).
6 Clamp (carburetor joint) 1 Loosen the screws (carburetor joint).
7 Hot starter plunger 1
8 Carburetor 1
9 Cylinder head breather pipe 1
10 Cylinder head breather hose 1 1
1

4 - 24
ENGCAMSHAFTS
CAMSHAFTS
CYLINDER HEAD COVER
Extent of removal:
1 Cylinder head cover removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD COVER
REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM”
section.
Engine upper bracket (right) Refer to “ENGINE REMOVAL” section.
Engine upper bracket (left)
1 Spark plug 1
2 Cylinder head breather hose 1
3 Bolt (cylinder head cover) 2
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
1

4 - 33
ENGCYLINDER HEAD
CYLINDER HEAD
CYLINDER HEAD
Extent of removal:
1 Cylinder head removal
NOTE:
Tighten the cylinder head bolts to 30 Nm (3.0 m  kg, 22 ft  lb) in the proper tightening sequence, remove and
retighten the cylinder head bolts to 20 Nm (2.0 m  kg, 14 ft  lb) in the proper tightening sequence, and then
tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence.
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Radiator Refer to “RADIATOR” section.
Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM” section.
Carburetor Refer to “CARBURETOR” section.
Camshaft Refer to “CAMSHAFTS” section.
1Bolt 2
2* Bolt 4 Refer to NOTE.
3 Cylinder head 1
4 Gasket 1
5 Dowel pin 2
6 Timing chain guide (front) 1
1