2009 YAMAHA WR 450F Owners Manual

7-6
ELECTRIC STARTING SYSTEM
3. Inspect:
• Secondary coil resistance
Out of specification→Replace.
4. Inspect:
• Sealed portion of ignition coil "a"
• Spark plug terminal pin "b"
• Threaded portion of spark plug "c"
Wear →Replace.
CHECKING THE AC MAGNETO
1. Inspect:
• Pickup coil resistance
Out of specification→Replace.CHECKING THE NEUTRAL
SWITCH
1. Inspect:
• Neutral switch conduction
Not conductive while it is in neutral→
Replace.
Conductive while it is engaged→Re-
place.
Set the tester selection position to "Ω
× 1".
CHECKING THE CDI UNIT
Check all electrical components. If no
fault is found, replace the CDI unit.
Then check the electrical compo-
nents again.
ELECTRIC STARTING
SYSTEM
STARTING CIRCUIT CUT-OFF
SYSTEM OPERATION
If the main switch is set to "ON", the
starter motor can only operate if at
least one of the following conditions is
met:
• The transmission is in neutral (the
neutral switch is closed).
• The clutch lever is pulled to the han-
dlebar (the clutch switch is closed).
The starting circuit cut-off relay pre-
vents the starter motor from operating
when neither of these conditions has
been met. In this instance, the start-
ing circuit cut-off relay is open so cur-
rent cannot reach the starter motor.
When at least one of the above con-
ditions has been met the starting cir-
cuit cut-off relay is closed and the
engine can be started by pressing the
start switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE CLUTCH LEVER IS
PULLED TO THE HANDLEBAR1. Battery
2. Main fuse
3. Main switch
4. Starting circuit cut-off relay
5. Start switch
6. Diode
7. Clutch switch
8. Neutral switch
9. Starter relay
10. Starter motor Tester (+) lead→Orange lead "1"
Tester (-) lead→Spark plug termi-
nal "2"
Secondary
coil resis-
tanceTester se-
lector posi-
tion
4.6–6.8
kΩat 20 °C
(68 °F) kΩ × 1
Tester (+) lead→Red lead "1"
Tester (-) lead→White lead "2"
Pickup coil
resistanceTester se-
lector posi-
tion
248–372 Ω
at 20 °C (68
°F) Ω × 100
Tester (+) lead→Sky blue lead "1"
Tester (-) lead→Ground "2"
Result
Conductive (while gear
is in neutral)

7-7
ELECTRIC STARTING SYSTEM
INSPECTION STEPS
If the starter motor will not operate, use the following inspection steps.
*1 marked: Refer to "CHECKING THE FUSE" section in the CHAPTER 3.
*2 marked: Refer to "CHECKING AND CHARGING THE BATTERY" section in the CHAPTER 3.
*3 marked: Refer to "CHECKING THE MAIN SWITCH" section.
*4 marked: Refer to "CHECKING THE NEUTRAL SWITCH" section.
• Remove the following parts before inspection.
1. Seat
2. Rear fender
• Use 12 V battery in this inspection.
• Use the following special tools in this inspection.
*1 Check fuse. No good→Replace fuse and check wire harness.
OK↓
*2 Check battery. No good→Recharge or replace.
OK↓
Check each coupler and wire connection. No good→Repair or replace.
OK↓
*3 Check main switch. No good→Replace.
OK↓
Check starter motor operation. No good→Repair or replace.
OK↓
Check starting circuit cut-off relay. No good→Replace.
OK↓
Check starter relay. No good→Replace.
OK↓
*4 Check neutral switch. No good→Replace.
OK↓
Check clutch switch. No good→Replace.
OK↓
Check diode. No good→Replace.
OK↓
Check start switch. No good→Replace.
Pocket tester:
YU-3112-C/90890-03112

7-8
ELECTRIC STARTING SYSTEM
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
CHECKING THE STARTER
MOTOR OPERATION
1. Connect the positive battery ter-
minal "1" and starter motor lead
"2" with a jumper lead "3".
Not operate→Repair or replace
the starter motor.
• A wire that is used as a jumper
lead must have at least the same
capacity or more as that of the
battery lead, otherwise the jump-
er lead may burn.
• This check is likely to produce
sparks, therefore make sure
nothing flammable is in the vicin-
ity.
CHECKING THE STARTING
CIRCUIT CUT-OFF RELAY
1. Remove:
• Starting circuit cut-off relay
2. Inspect:
• Starting circuit cut-off relay con-
duction
Use 12 V battery.
Not conductive while the battery is
connected→Replace.
Conductive while the battery is not
connected→Replace.
Set the tester selection position to "Ω
× 1".
CHECKING THE STARTER RELAY
1. Remove:
• Starter relay
2. Inspect:
• Starter relay conduction
Use 12 V battery.
Not conductive while the battery is
connected→Replace.
Conductive while the battery is not
connected →Replace.
Set the tester selection position to "Ω
× 1".
CHECKING THE CLUTCH SWITCH
1. Inspect:
• Clutch switch conduction
Not conductive while it is pulled→Re-
place.
Conductive while it is freed→Re-
place.
Set the tester selection position to "Ω
× 1".
CHECKING THE DIODE
1. Remove the diode from wire har-
ness.
2. Inspect:
• Diode continuity
Use pocket tester (tester selec-
tion position Ω × 1)
Incorrect continuity→Replace. Battery (+) lead→Blue/Black lead
"1"
Battery (-) lead→Brown lead "2"
Tester (+) lead→Blue/White lead
"3"
Tester (-) lead→Black lead "4"
Result
Conductive (while the
battery is connected)
Battery (+) lead→Starter relay ter-
minal "1"
Battery (-) lead→Starter relay ter-
minal "2"
Tester (+) lead→Starter relay ter-
minal "3"
Tester (-) lead→Starter relay ter-
minal "4"
Result
Conductive (while the
battery is connected)
Tester (+) lead→Black lead "1"
Tester (-) lead→Black lead "2"
Result
Conductive (while the
clutch lever is pulled)
Tester (+)→Blue/Red
terminal "1"
Tester (-) →Sky blue
terminal "2"Continu-
ous
Tester (+)→Blue/Red
terminal "1"
Tester (-)→Blue/Yel-
low terminal "3"Continu-
ous
Tester (+)→Sky blue
terminal "2"
Tester (-)→Blue/Red
terminal "1"No con-
tinuous
Tester (+)→Blue/Yel-
low terminal "3"
Tester (-)→Blue/Red
terminal "1"No con-
tinuous

7-9
ELECTRIC STARTING SYSTEM
CHECKING THE START SWITCH
1. Inspect:
• Start switch conduction
Not conductive while it is pushed→
Replace.
Conductive while it is freed→Re-
place.
Set the tester selection position to "Ω
× 1".
2. Inspect:
• Rubber part "a"
Tears/damage→Replace. Tester (+) lead→Black lead "1"
Tester (-) lead→Black lead "2"
Result
Conductive (while the
start switch is pushed)

7-10
ELECTRIC STARTING SYSTEM
REMOVING THE STARTER MOTOR
Order Part name Q'ty Remarks
Exhaust pipeRefer to "REMOVING THE EXHAUST PIPE
AND SILENCER" section in the CHAPTER 3.
1 Starter motor 1

7-11
ELECTRIC STARTING SYSTEM
DISASSEMBLING THE STARTER MOTOR
Order Part name Q'ty Remarks
1 Starter motor front cover 1
2 Washer (starter motor front cover) 1
3 Washer 1
4 Circlip 1
5O-ring 1
6 Starter motor yoke 1
7 Armature assembly 1
8 Starter motor rear cover 1
9 Brush 2
10 Brush spring 2

7-12
ELECTRIC STARTING SYSTEM
CHECKING AND REPAIRING THE
STARTER MOTOR
1. Check:
• Commutator
Dirt→Clean with 600 grit sandpa-
per.
2. Measure:
• Commutator diameter "a"
Out of specification→Replace the
starter motor.
3. Measure:
• Mica undercut "a"
Out of specification→Scrape the
mica to the proper measurement
with a hacksaw blade which has
been grounded to fit the commu-
tator.
The mica must be undercut to ensure
proper operation of the commutator.
4. Measure:
• Armature assembly resistances
(commutator and insulation)
Out of specification→Replace the
starter motor.
a. Measure the armature assembly
resistances with the pocket tester.b. If any resistance is out of specifi-
cation, replace the starter motor.
5. Measure:
• Brush length "a"
Out of specification→Replace the
brushes as a set.
6. Measure:
• Brush spring force
Out of specification→Replace the
brush springs as a set.ASSEMBLING THE STARTER
MOTOR
1. Install:
• Brush spring "1"
• Brush "2"
2. Install:
• Armature assembly "1"
Install while holding down the
brush using a thin screw driver.
Be careful not to damage the brush
during installation.
3. Install:
• O-ring "1"
• Starter motor yoke "2"
• Align the match mark "a" on the
starter motor yoke with the match
mark "b" on the starter motor rear
cover.
• Install the starter motor yoke with its
groove "c" facing rear cover.
Min. commutator diame-
ter:
16.6 mm (0.65 in)
Mica undercut:
1.5 mm (0.06 in)
Pocket tester:
YU-3112-C/90890-
03112
Armature assembly:
Commutator resis-
tance "1":
0.0117–0.0143 Ω at 20
°C (68 °F)
Insulation resistance
"2":
Above 1 MΩat 20 °C
(68 °F)
Min. brush length:
3.5 mm (0.14 in)
Brush spring force:
3.92–5.88 N (400–600
gf, 14.1–21.2 oz)

7-13
ELECTRIC STARTING SYSTEM
4. Install:
• O-ring "1"
• Circlip
• Plain washer "2"
• Washer (starter motor front cover)
"3"
• Starter motor front cover "4"
• For installation, align the projec-
tions on the washer with the slots in
the front cover.
• Align the match mark "a" on the
starter motor yoke with the match
mark "b" on the starter motor front
cover.
5. Install:
•Bolt "1"
• O-ring "2"
Apply the lithium soap base grease
on the O-ring.