2007 YAMAHA WR 450F brake

3 - 47
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Clutch lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Clutch cable end
0Hot starter cable endÈUse Yamaha cable lube or equivalent on these
areas.
ÉUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÊLubricate the following areas with high quality,
lightweight lithium-soap base grease.
CAUTION:
Wipe off any excess grease, and avoid get-
ting grease on the brake discs.
AAA
AA
B
CC

4 - 52
ENGCLUTCH
CLUTCH
CLUTCH
Extent of removal:
1 Push rod and push lever removal
2 Push rod 1 disassembly
3 Friction plate and clutch plate removal
4 Clutch housing removal
Extent of removal Order Part name Q’ty Remarks
CLUTCH REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Gasket 1
3 Dowel pin 2
4 Clutch spring 6
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8 Plain washer 1
9 Bearing 1
10 Ball 1
11 Push rod 2 1
1
2
34
1

4 - 59
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

4 - 90
ENGENGINE REMOVAL
Extent of removal:
1 Engine removal
Extent of removal Order Part name Q’ty Remarks
Cylinder head breather hose Refer to “CAMSHAFTS” section.
Ignition coil
Disconnect the AC magneto lead.
Disconnect the starter motor
lead.Refer to “ELECTRIC STARTING SYS-
TEM” section in the CHAPTER 6.
Negative battery lead Disconnect at the starter motor side.
1 Engine guard 1
2 Neutral switch 1
3 Chain cover 1
4 Nut (drive sprocket) 1
Refer to “REMOVAL POINTS”. 5 Lock washer 1
6 Drive sprocket 1
7Clip 1
8 Bolt (brake pedal) 1
9 Brake pedal 1
1

4 - 92
ENGENGINE REMOVAL
EC4M3000
REMOVAL POINTS
EC4F3100
Drive sprocket
1. Remove:
Nut (drive sprocket) 1
Lock washer 2
NOTE:
Straighten the lock washer tab.
Loosen the nut while applying the rear brake.
2. Remove:
Drive sprocket 1
Drive chain 2
NOTE:
Remove the drive sprocket together with the
drive chain.
EC4M3301
Engine removal
1. Remove:
Pivot shaft 1
NOTE:
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.
2. Remove:
Engine 1
From right side.
NOTE:
Make sure that the couplers, hoses and cables
are disconnected.
1

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ENGENGINE REMOVAL
EC4M5000
ASSEMBLY AND INSTALLATION
Engine installation
1. Install:
Engine 1
Install the engine from right side.
Pivot shaft 2
Engine mounting bolt (lower) 3
Engine lower bracket 4
Bolt (engine lower bracket) 5
Patch 6
Engine mounting bolt (front) 7
Engine upper bracket (right) 8
Engine upper bracket (left) 9
Bolt (engine upper bracket) 0
Engine mounting bolt (upper) A
NOTE:
Apply the molybdenum disulfide grease on
the pivot shaft.
Install the patch with the claw a facing out-
side the chassis.
T R..85 Nm (8.5 m · kg, 61 ft · lb)
T R..53 Nm (5.3 m · kg, 38 ft · lb)
T R..34 Nm (3.4 m · kg, 24 ft · lb)
T R..53 Nm (5.3 m · kg, 38 ft · lb)
T R..55 Nm (5.5 m · kg, 40 ft · lb)
T R..55 Nm (5.5 m · kg, 40 ft · lb)
Brake pedal
1. Install:
Spring 1
Brake pedal 2
O-ring 3
Bolt (brake pedal) 4
Clip 5
NOTE:
Apply the lithium soap base grease on the bolt,
O-rings and brake pedal bracket.
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)

4 - 94
ENGENGINE REMOVAL
Drive sprocket
1. Install:
Drive sprocket 1
Drive chain 2
NOTE:
Install the drive sprocket together with the
drive chain.
2. Install:
Lock washer 1
Nut (drive sprocket) 2
NOTE:
Tighten the nut while applying the rear brake.
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)
3. Bend the lock washer tab to lock the nut.
4. Install:
Chain guide
Chain cover 1
Screw (chain cover) 2
21T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
5. Install:
Spring 1
Pin 2
O-ring 3
Neutral switch 4
Screw (neutral switch) 5
NOTE:
Apply the lithium soap base grease on the O-
ring.
New
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)

5 - 1
CHAS
EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1 Front wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
1 Bolt (axle holder) 4 Only loosening.
2 Nut (front wheel axle) 1
3 Front wheel axle 1
4 Front wheel 1
5 Speed sensor 1
6 Collar 1
7 Oil seal 1
8 Bearing 2 Refer to “REMOVAL POINTS”.
9 Brake disc 1
2
13
3