2007 YAMAHA WR 450F light

5 - 23
CHASFRONT BRAKE AND REAR BRAKE
4. Pass the brake hose through the hose
guides 1.
5. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that it contacts the
master cylinder projection
a and that its
bent portion
b faces downward.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
Rear brake hose
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the caliper.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)

5 - 26
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:
1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK 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.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Headlight
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Pinch bolt (handle crown) 2 Only loosening.
3 Cap bolt 1 Loosen when disassembling the front fork.
4 Pinch bolt (under bracket) 2 Only loosening.
5 Front fork 1
1

5 - 39
CHAS
EC5B0000
HANDLEBAR
Extent of removal:
1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
HANDLEBAR REMOVAL
Preparation for removal Headlight
1 Hot starter cable 1 Disconnect at the lever side.
2 Hot starter lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1 Disconnect the clutch switch lead.
5“ENGINE STOP” button 1 Disconnect the “ENGINE STOP” button
lead.
6 Master cylinder 1 Refer to “REMOVAL POINTS”.
7 Start switch 1 Disconnect the start switch lead.
8 Throttle cable cap 1
9 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
10 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
11 Grip (right) 1 Refer to “REMOVAL POINTS”.
12 Tube guide 1
13 Grip (left) 1 Refer to “REMOVAL POINTS”.
14 Handlebar holder (upper) 2
15 Handlebar 1
16 Handlebar holder (lower) 2
1
HANDLEBAR

5 - 46
CHAS
EC560000
STEERING
Extent of removal:
1 Under bracket removal
2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING 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.
Headlight
Handlebar Refer to “HANDLEBAR” section.
Hose guide
Front fender
1 Multi-function meter 1
2 Multi-function meter bracket 1
3 Main switch 1 Disconnect the main switch lead.
4 Steering shaft nut 1
5 Front fork 2 Refer to “FRONT FORK” section.
6 Handle crown 1
7 Ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
8 Under bracket 1
9 Bearing race cover 1
21
STEERING

5 - 61
CHASREAR SHOCK ABSORBER
Extent of removal Order Part name Q’ty Remarks
Cylinder head breather hose Disconnect at the air filter case side.
Battery Refer to “BATTERY INSPECTION AND
CHARGING” section in the CHAPTER 3.
Disconnect the starter relay cou-
pler.
Starter motor lead Disconnect at the starter relay side.
1 Locking tie 4
2 Taillight coupler 1
3 CDI unit coupler 3
4 Plastic band 1
5 Clamp (air filter joint) 1 Only loosening.
6Rear frame 1
7 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
8 Bolt (rear shock absorber-frame) 1
21

5 - 68
CHAS
8. Install:
•Plastic band
•Taillight coupler
•Locking tie
REAR SHOCK ABSORBER

6 - 1
–+ELECELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC600000
ELECTRICAL
EC610000
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
EC611000
ELECTRICAL COMPONENTS
1Headlight
2Multi-function display
3“ENGINE STOP” but-
ton
4Clutch switch
5Diode
6Starter relay diode
7TPS (throttle posi-
tion sensor)
8Starter relay
9Fuse
0Starting circuit cut-off
relayACDI unit
BTaillight
CNeutral switch
DStarter motor
EAC magneto
FRectifier/regulator
GIgnition coil
HSpark plug
IStart switch
JMain switch
KSpeed sensor
LBatteryCOLOR CODE
B ...................... Black
Br ..................... Brown
Ch .................... Chocolate
Dg .................... Dark green
G ...................... Green
Gy .................... Gray
L....................... Blue
O ...................... Orange
R ...................... Red
Sb .................... Sky blue
EC612000
WIRING DIAGRAM
W ..................... White
Y ...................... Yellow
B/L ................... Black/Blue
B/W .................. Black/White
L/B ................... Blue/Black
L/R ................... Blue/Red
L/Y ................... Blue/Yellow
L/W .................. Blue/White
R/B................... Red/Black
R/W.................. Red/White

6 - 4
–+ELECIGNITION SYSTEM
MAIN SWITCH INSPECTION
1. Inspect:
•Main switch conduct
Continuous while the main switch is moved to
“OFF” → Replace.
Not continuous while the main switch is moved
to “ON” → Replace.
2. Inspect:
•Main switch indicator light
Use 12 V battery.
Indicator light does not come on → Replace.
3. Inspect:
•Rubber part a
Tears/damage → Replace. Tester (+) lead
→ Red lead
1
Tester (–) lead
→ Brown lead
2
R
1 Br
2 Tester selec-
tor position
ON
Ω
×
×× × 1
OFF
Battery (+) lead
→ Red/Black lead
1
Battery (–) lead
→ Black lead
2
a
EC626002
IGNITION COIL INSPECTION
1. Remove the ignition coil cap.
2. Inspect:
•Primary coil resistance
Out of specification → Replace.
Tester (+) lead
→ Orange lead
1
Tester (–) lead
→ Black lead
2
Primary coil
resistanceTester selector
position
0.08 ~ 0.10
Ω at
20 °C (68 °F)Ω
× 1