2008 YAMAHA WR 450F brake sensor

CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............. 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING OF CONNEC-
TION ................................. 1-3
SPECIAL TOOLS ............. 1-4
CONTROL FUNCTIONS .. 1-8
MULTI-FUNCTION
DISPLAY .......................... 1-9
STARTING AND
BREAK-IN ...................... 1-14
TORQUE-CHECK
POINTS........................... 1-16
CLEANING AND
STORAGE ...................... 1-17
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICA-
TIONS ............................... 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-4
TIGHTENING
TORQUES ...................... 2-13
LUBRICATION
DIAGRAMS .................... 2-19
CABLE ROUTING
DIAGRAM ....................... 2-21
CHAPTER 3
REGULAR INSPEC-
TION AND AD-
JUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-5
ENGINE ............................ 3-6
CHASSIS ........................ 3-17
ELECTRICAL ................. 3-27
CHAPTER 4
TUNING
ENGINE ............................ 4-1
CHASSIS .......................... 4-5
CHAPTER 5
ENGINE
RADIATOR ....................... 5-1
CARBURETOR................. 5-4
AIR INDICTOIN
SYSTEM ......................... 5-13
CAMSHAFTS.................. 5-15
CYLINDER HEAD........... 5-20
VALVES AND VALVE
SPRINGS ........................ 5-23
CYLINDER AND
PISTON ........................... 5-27
CLUTCH ......................... 5-30
OIL FILTER ELEMENT
AND WATER PUMP ....... 5-34
BALANCER .................... 5-38
OIL PUMP ....................... 5-40
KICK SHAFT AND SHIFT
SHAFT ............................ 5-43
AC MAGNETO AND
STARTER CLUTCH ....... 5-48
ENGINE REMOVAL ....... 5-53CRANKCASE AND
CRANKSHAFT ...............5-57
TRANSMISSION, SHIFT
CAM AND SHIFT
FORK ..............................5-63
CHAPTER 6
CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................6-1
FRONT BRAKE AND
REAR BRAKE ..................6-6
FRONT FORK .................6-16
HANDLEBAR..................6-23
STEERING ......................6-27
SWINGARM ....................6-31
REAR SHOCK
ABSORBER ....................6-36
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPO-
NENTS AND WIRING DIA-
GRAM ...............................7-1
IGNITION SYSTEM...........7-3
ELECTRIC STARTING
SYSTEM............................7-5
CHARGING SYSTEM .....7-13
THROTTLE POSITION
SENSOR SYSTEM .........7-15
LIGHTING SYSTEM .......7-18
SIGNALING SYSTEM.....7-20

2-16
TIGHTENING TORQUES
△Driven sprocket and wheel hub M8 × 1.25 6 50 5.0 36
△Nipple (spoke) — 72 3 0.3 2.2
△Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2
△Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
△Engine upper bracket and frame M10 × 1.25 4 55 5.5 40
△Engine lower bracket and frame M8 × 1.25 4 34 3.4 24
△Engine and engine bracket (lower) M10 × 1.25 1 53 5.3 38
△Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
△Engine and frame (lower) M10 × 1.25 1 53 5.3 38
△Engine guard M6 × 1.0 3 7 0.7 5.1
Regulator mounting M6 × 1.0 2 7 0.7 5.1
△Pivot shaft and nut M16 × 1.5 1 85 8.5 61
△Relay arm and swingarm M14 × 1.5 1 70 7.0 50
△Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
△Connecting rod and frame M14 × 1.5 1 80 8.0 58
△Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
△Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
△Rear frame and frame (upper) M8 × 1.25 1 38 3.8 27
△Rear frame and frame (lower) M8 × 1.25 2 32 3.2 23
△Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Drive chain tensioner mounting (upper) M8 × 1.25 1 16 1.6 11
Drive chain tensioner mounting (lower) M8 × 1.25 1 16 1.6 11
Chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
△Fuel tank mounting M6 × 1.0 2 9 0.9 6.5
△Fuel tank and fuel cock M6 × 1.0 2 4 0.4 2.9
Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
△Seat mounting M8 × 1.25 2 23 2.3 17
△Side cover mounting M6 × 1.0 2 7 0.7 5.1
△Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
△Air scoop and radiator panel (lower) M6 × 1.0 2 6 0.6 4.3
△Front fender mounting M6 × 1.0 4 7 0.7 5.1
△Rear fender mounting(front) M6 × 1.0 2 7 0.7 5.1
△Rear fender mounting (rear) M6 × 1.0 2 11 1.1 8.0
Multi-function display bracket mounting M6 × 1.0 2 7 0.7 5.1
Multi-function display mounting M5 × 0.8 2 4 0.4 2.9
Plate 1 and protector M5 × 0.8 2 4 0.4 2.9
Plate 2 and protector — 2 0.5 0.05 0.36
Speed sensor lead holder and under bracket M6 × 1.0 1 13 1.3 9.4
Headlight body and headlight unit — 2 1 0.1 0.7Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb

2-21
CABLE ROUTING DIAGRAM
CABLE ROUTING DIAGRAM
1. Fuel tank breather hose
2. Clamp
3. Diode
4. Hot starter cable
5. Throttle position sensor lead
6. Wire harness
7. Hump (frame)
8. Negative battery lead
9. Starter motor lead10. Neutral switch lead
11. AC magneto lead
12. Brake hose
13. Rectifier/regulator lead
14. Carburetor breather hose
15. Carburetor overflow hose
16. Catch tank breather hoseA. Insert the end of the fuel tank
breather hose into the hole in
the steering stem.
B. Fasten the throttle cable, hot
starter cable and rectifier/regula-
tor lead onto the frame. Locate
the clamp end facing the lower
side of the hot starter cable and
cut off the tie end.

2-27
CABLE ROUTING DIAGRAM
1. Throttle cable
2. Clamp
3. Brake hose
4. Clutch cable
5. Hose guide
6. Main switch coupler
7. Wire harness
8. Headlight coupler
9. Hot starter cable
10. Multi-function display bracket11. Main switch
12. Upper bracket
13. Clutch switch coupler
14. Engine stop switch coupler
15. Multi-function display coupler
16. Start switch coupler
17. Speed sensor coupler
18. Speed sensor leadA. Fasten the start switch lead to
the handlebar with the plastic
bands.
B. Fasten the engine stop switch
lead and clutch switch lead to
the handlebar with the plastic
bands.
C. Pass the brake hose through
the hose guides.

6-1
FRONT WHEEL AND REAR WHEEL
CHASSIS
FRONT WHEEL AND REAR WHEEL
REMOVING THE FRONT WHEEL
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
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 section.
9 Brake disc 1
21 Nm (2.1 m kg, 15 ft lb)
21 Nm (2.1 m kg, 15 ft lb)
12 Nm (1.2 m kg, 8.7 ft lb)
90 Nm (9.0 m kg, 65 ft lb)

6-4
FRONT WHEEL AND REAR WHEEL
2. Install:
• Brake disc "1"
• Bolt (brake disc) "2"
Tighten the bolts in stage, using a
crisscross pattern.
3. Install:
•Collar "1"
Apply the lithium soap base grease
on the oil seal lip.
4. Install:
• Speed sensor "1"
• Apply the lithium soap base grease
on the oil seal lip of the speed sen-
sor.
• Make sure the two projections "a" in
the wheel hub are meshed with the
two slots "b" in the speed sensor.
5. Install:
• Wheel
• Install the brake disc "1" between
the brake pads "2" correctly.
• Make sure that the projections "a" in
the speed sensor fits over the stop-
per "b" on the front fork inner tube.
6. Install:
• Wheel axle "1"
Apply the lithium soap base grease
on the wheel axle.
7. Install:
• Nut (wheel axle) "1"
8. Tighten:
• Bolt (axle holder) "1"
Before tightening the bolt, fit the
wheel axle to the axle holder by strok-
ing the front fork several times with
the front brake applied.
INSTALLING THE REAR WHEEL
1. Install:
• Bearing (right) "1"
• Circlip "2"
• Spacer "3"
• Bearing (left) "4"
• Oil seal "5"
• Apply the lithium soap base grease
on the bearing and oil seal lip when
installing.
• Install the bearing with seal facing
outward.
• Use a socket that matches the out-
side diameter of the race of the
bearing.
• Right side of bearing shall be in-
stalled first.
• Install the oil seal with its manufac-
ture's marks or numbers facing out-
ward.
Do not strike the inner race of the
bearing. Contact should be made
only with the outer race.
Bolt (brake disc):
12 Nm (1.2 m•kg, 8.7
ft•lb)
Nut (wheel axle):
90 Nm (9.0 m•kg, 65
ft•lb)
Bolt (axle holder):
21 Nm (2.1 m•kg, 15
ft•lb)

6-30
STEERING
6. Install:
• Washer "1"
7. Install:
• Front fork "1"
• Upper bracket "2"
• Main switch "3"
• Front brake hose guide bracket
"4"
• Temporarily tighten the pinch bolts
(lower bracket).
• Do not tighten the pinch bolts (up-
per bracket) yet.
8. Install:
• Guide (speed sensor lead) "1"
After installing the guide as shown,
pass the speed sensor lead through
the guide.
9. Install:
• Washer "1"
• Steering stem nut "2"10. After tightening the nut, check the
steering for smooth movement. If
not, adjust the steering by loosen-
ing the steering ring nut little by lit-
tle.
11. Adjust:
• Front fork top end "a"
12. Tighten:
• Pinch bolt (upper bracket) "1"
• Pinch bolt (lower bracket) "2"
Tighten the lower bracket to speci-
fied torque. If torqued too much, it
may cause the front fork to mal-
function.
13. Install:
• Multi-function display bracket "1"
• Multi-function display "2"
Pass the throttle cables "3", clutch ca-
ble "4" and hot starter cable "5" be-
tween the multi-function display
bracket and upper bracket.
14. Install:
• Holder "1"
• Clamp "2"
• Install so that the marking "a" on the
speed sensor lead aligns with the
holder edge.
• Fasten the speed sensor lead to the
holder with the clamp.
Steering stem nut:
145 Nm (14.5 m•kg, 105
ft•lb)
Front fork top end (stan-
dard) "a":
Zero mm (Zero in)
Pinch bolt (upper brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
Pinch bolt (lower brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
Multi-function display
bracket:
7 Nm (0.7 m•kg, 5.1
ft•lb)
Multi-function display:
4 Nm (0.4 m•kg, 2.9
ft•lb)
Holder:
13 Nm (1.3 m•kg, 9.4
ft•lb)
Clamp:
7 Nm (0.7 m•kg, 5.1
ft•lb)