2007 YAMAHA WR 450F ignition

CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM ...........................6-1
IGNITION SYSTEM ....................................6-2
ELECTRIC STARTING SYSTEM ..............6-6
CHARGING SYSTEM ..............................6-16
TPS (THROTTLE POSITION SENSOR)
SYSTEM ...................................................6-18
LIGHTING SYSTEM ................................6-23
SIGNALING SYSTEM ..............................6-26
CHAPTER 7
TUNING
ENGINE ......................................................7-1
CHASSIS ...................................................7-9

GEN
INFO
1 - 8
SPECIAL TOOLS
YS-1880-A, 90890-01701 Sheave holder
This tool is used for when loosening or tightening the
flywheel magneto securing nut.YS-1880-A 90890-01701
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-3112-C 90890-03112
YM-33277-A, 90890-03141 Timing light
This tool is necessary for checking ignition timing.YM-33277-A 90890-03141
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-4019 90890-04019
YM-91042, 90890-04086 Clutch holding tool
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.YM-91042 90890-04086
YM-4116, 90890-04116
YM-4097, 90890-04097Valve guide remover
Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)
This tool is needed to remove and install the valve
guide.YM-4116
YM-409790890-04116
90890-04097
YM-4117, 90890-04117
YM-4098, 90890-04098Valve guide installer
Intake
Exhaust
This tool is needed to install the valve guide.YM-4117
YM-409890890-04117
90890-04098
YM-4118, 90890-04118
YM-4099, 90890-04099Valve guide reamer
Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)
This tool is needed to rebore the new valve guide.YM-4118
YM-4099 90890-04118
90890-04099
YM-04142, 90890-04142 Rotor puller
This tool is used to remove the flywheel magneto.YM-04142 90890-04142
Part number Tool name/How to use Illustration

GEN
INFO
1 - 9
SPECIAL TOOLS
YU-A9642, 90890-04152 Crankcase separating tool
These tool is used to remove the crankshaft from
either case.YU-A9642 90890-04152
YM-34487
90890-06754Dynamic spark tester
Ignition checker
This instrument is necessary for checking the ignition
system components.YM-34487 90890-06754
YB-35956-A, 90890-06756 Vacuum/pressure pump gauge set
This tool is used to check the air induction system.YB-35956-A 90890-06756
90890-85505 YAMAHA Bond No. 1215
(ThreeBond
® No. 1215)
This sealant (Bond) is used for crankcase mating sur-
face, etc.90890-85505 90890-85505
Part number Tool name/How to use Illustration

1 - 22
GEN
INFO
STARTING AND BREAK-IN
STARTING AND BREAK-IN
WARNING
Never start or run the engine in a closed
area. The exhaust fumes are poisonous;
they can cause loss of consciousness and
death in a very short time. Always operate
the machine in a well-ventilated area.
CAUTION:
The carburetor on this machine has a
built-in accelerator pump. Therefore,
when starting the engine, do not operate
the throttle or the spark plug will foul.
Unlike a two-stroke engine, this engine
cannot be kick started when the throttle is
open because the kickstarter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the
engine to start.
Before starting the machine, perform the
checks in the pre-operation check list.
AIR FILTER MAINTENANCE
According to “AIR FILTER CLEANING” section
in the CHAPTER 3, apply the foam-air-filter oil
or its equivalent to the element. (Excess oil in
the element may adversely affect engine start-
ing.)
STARTING A COLD ENGINE
NOTE:
This model is equipped with an ignition circuit
cut-off system. The engine can be started
under the following conditions.
When the transmission is in neutral.
When the clutch is disengaged with the
transmission in any position. However, it is
recommended to shift into neutral before
starting the engine.
1. Inspect the coolant level.
2. Turn the fuel cock to “ON”.
3. Push the main switch to “ON”.
4. Shift the transmission into neutral.
5. Fully open the cold starter knob 1.
6. Start the engine by pushing the start switch
or by kicking the kickstarter.
1

SPEC
2 - 3 Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 305 mm (12.0 in)
Electrical:
Ignition system CDI
Generator system AC magneto
Battery type YTZ7S
Battery voltage/capacity 12 V/6 AH
Specific gravity 1.310
Headlight type: Quartz bulb (halogen)
Bulb wattage × quantity:
Headlight 12 V 35/36.5 W × 1
Taillight 12 V 1.6/0.3 W × 1
GENERAL SPECIFICATIONS

SPEC
2 - 18
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
C.D.I.:
Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)
(White – Red)----
CDI unit-model/manufacturer 5TJ-E0/YAMAHA (For USA)
5TJ-F0/YAMAHA
(Except for USA)----
----
Ignition coil:
Model/manufacturer 5TA-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ----
Secondary winding resistance 4.6 ~ 6.8 kΩ at 20 °C (68 °F) ----
Charging system:
System type AC magneto ----
Model (stator)/manufacturer 5TJ 40/YAMAHA ----
Normal output 14 V/120 W at 5,000 r/min ----
Charging coil resistance (color) 0.288 ~ 0.432 Ω at 20 °C (68 °F)
(White – Ground)----
Lighting coil resistance (color) 0.224 ~ 0.336 Ω at 20 °C (68 °F)
(Yellow – Ground)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH770AA/SHINDENGEN ----
Regulated voltage (AC) 12.5 ~ 13.5 V ----
Regulated voltage (DC) 14.0 ~ 15.0 V ----
Rectifier capacity (AC) 12 A ----
Rectifier capacity (DC) 8 A ----
Electric starting system:
Type Constant mesh ----
Starter motor:
Model/manufacturer 5UM20/YAMAHA ----
Operation voltage 12 V ----
Output 0.48 kW ----
Armature coil resistance 0.0117 ~ 0.0143 Ω at 20 °C
(68 °F)----
Brush overall length 7 mm (0.28 in) 3.5 mm
(0.14 in)
Brash quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm
(0.65 in)
Mica undercut (depth) 1.5 mm (0.06 in) ----
MAINTENANCE SPECIFICATIONS

2 - 26
SPECCABLE ROUTING DIAGRAM
1Throttle cable (pull)
2Throttle cable (return)
3Catch tank hose
4Ignition coil
5Clamp
6Air induction hose (air cut-off valve - rear of cyl-
inder head)
7Catch tank breather hoseÈCross the pull and push throttle cables.
ÉFasten the catch tank hose and air induction
hose (air cut-off valve - rear of cylinder head)
onto the frame. Locate the clamp end facing
toward the lower side of the frame and cut off the
tie end.
ÊFasten the catch tank breather hose and carbu-
retor breather hoses together.
ËPass the carburetor breather hose (of the throt-
tle cable cover) through the hose holder.

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-21
Engine oilCheck that the oil level is correct. Check the crankcase and oil
line for leakage.P.3-14 ~ 18
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9 ~ 10
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10 ~ 11
Brakes Check the play of front brake and effect of front and rear brake. P.3-25 ~ 31
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-32 ~ 35
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-43 ~ 44
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-44 ~ 46
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-35 ~ 42
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or when
the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks.—
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-32
Lubrication Check for smooth operation. Lubricate if necessary. P.3-47
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-26
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 20