User Manuals: Yamaha WR450FM 2021 Off-Road Motorcycle

Manuals and User Guides for Yamaha WR450FM 2021 Off-Road Motorcycle. We have 1 Yamaha WR450FM 2021 Off-Road Motorcycle manual available for free PDF download: Owner's Service Manual

Yamaha WR450FM 2021 Owner's Service Manual

Yamaha WR450FM 2021 Owner's Service Manual (402 pages)

Brand: Yamaha | Category: Motorcycle | Size: 25 MB

Table of Contents

Table of Contents

9
- For Safety, be Sure to Obey the Following
  13
- Safety Information
  13
- Location of Important Labels
  16
- Description
  17
- Identification
  18
- Vehicle Identification Number
  18
- Engine Serial Number
  18
- Vehicle Emission Control Information Label
  18
- Fuel Hose Joint Cover
  19
- Coupler for Connecting Optional Part
  19
- Handlebar Protector
  19
- Nipple Wrench
  19
- Included Parts
  19
- Important Information
  20
- Preparation for Removal and Disassembly
  20
- Replacement Parts
  20
- Gaskets, Oil Seals and O-Rings
  20
- Lock Washers/Plates and Cotter Pins
  21
- Bearings and Oil Seals
  21
- Circlips
  21
- Basic Service Information
  22
- Electrical System
  22
- Special Tools
  26
- Start Switch
  32
- Shift Pedal
  32
- Instrument and Control Functions
  32
- Warning Lights
  32
- Engine Stop Switch
  32
- Front Brake Lever
  33
- Rear Brake Pedal
  33
- Sidestand
  33
- Starter Knob
  33
- Fuel Tank Cap
  33
- Multi-Function Display
  36
- 20.Setting the Timer
  43
- 10.Setting Mode
  43
- Starting a Cold Engine
  44
- Starting and Break-In
  44
- Handling Note
  44
- Fuel
  44
- Starting a Warm Engine
  45
- Break-In Procedures
  45
- Shifting
  45
- Maintenance after Break-In
  47
- Major Maintenance
  47
- Air Filter Maintenance
  47
- Torque-Check Points
  48
- Motorcycle Care and Storage
  50
- Care
  50
- Storage
  51
Specifications

53
- General Specifications
  54
- Engine Specifications
  55
- Chassis Specifications
  60
- Electrical Specifications
  61
- General Tightening Torque Specifications
  63
- Tightening Torques
  63
- Engine Tightening Torques
  64
- Chassis Tightening Torques
  67
- Cable Routing Diagram
  72
Periodic Checks and Adjustments

89
- General Maintenance and Lubrication Chart
  91
- Introduction
  91
- Periodic Maintenance
  91
- Periodic Maintenance Chart for the Emission Control System
  91
- Maintenance Intervals for Competition Use
  93
- General Inspection and Maintenance
  96
- Pre-Operation Inspection and Maintenance
  96
- Adjusting the Valve Clearance
  97
- Engine
  97
- Valve Clearance Shim Chart
  100
- Checking the Engine Idling Speed
  102
- Checking the Throttle Grip
  102
- Checking the Spark Plug
  103
- Changing the Engine Oil
  104
- Checking the Engine Oil Level
  104
- Adjusting the Clutch Lever Free Play
  106
- Cleaning the Air Filter Element
  106
- Checking the Cylinder Head Breather Hose
  108
- Checking the Fuel Line
  108
- Checking the Throttle Body Joint
  108
- Checking the Exhaust System
  109
- Checking the Coolant Level
  110
- Changing the Coolant
  111
- Checking the Cooling System
  111
- Adjusting the Front Disc Brake
  113
- Adjusting the Rear Disc Brake
  113
- Chassis
  113
- Checking the Brake Fluid Level
  114
- Checking the Front Brake Hose
  114
- Checking the Front Brake Pads
  114
- Checking the Rear Brake Pads
  114
- Bleeding the Hydraulic Brake System
  115
- Checking the Brake Operation
  115
- Checking the Rear Brake Hose
  115
- Drive Chain Slack
  116
- Checking and Adjusting the Steering Head
  117
- Lubricating the Drive Chain
  117
- Checking the Front Fork Legs
  118
- Lubricating the Steering Head
  118
- Adjusting the Front Fork Legs
  119
- Adjusting the Rear Shock Absorber Assembly
  120
- Checking the Rear Shock Absorber Assembly
  120
- Checking the Connecting Arm and Relay Arm
  122
- Checking the Swingarm Operation
  122
- Lubricating the Swingarm Pivot
  122
- Checking and Tightening the Spokes
  123
- Checking the Tires
  123
- Checking the Wheel Bearings
  123
- Checking the Wheels
  123
- Checking and Lubricating the Cables
  124
- Checking the Chassis Fasteners
  124
- Checking the Sidestand
  124
- Lubricating the Brake Lever
  124
- Lubricating the Clutch Lever
  124
- Lubricating the Pedal
  124
- Lubricating the Sidestand
  124
- Checking and Charging the Battery
  125
- Checking the Fuses
  125
- Checking the Ignition Timing
  125
- Electrical System
  125
- Replacing the Headlight Bulb
  125
Chassis

127
- General Chassis
  132
- Installing the Air Scoop
  132
- Installing the Side Cover
  132
- Removing the Seat
  132
- Removing the Side Cover
  132
- Front Wheel
  134
- Checking the Front Wheel Sensor and Sensor Rotor
  135
- Disassembling the Front Wheel
  135
- Removing the Front Wheel
  135
- Assembling the Front Wheel
  136
- Checking the Front Wheel
  136
- Installing the Front Wheel
  138
- Rear Wheel
  140
- Checking and Replacing the Rear Wheel Sprocket
  141
- Checking the Rear Wheel
  141
- Disassembling the Rear Wheel
  141
- Removing the Rear Wheel
  141
- Assembling the Rear Wheel
  142
- Installing the Rear Wheel
  142
- Front Brake
  145
- Checking the Front Brake Disc
  148
- Introduction
  148
- Replacing the Front Brake Pads
  148
- Assembling the Front Brake Caliper
  150
- Checking the Front Brake Caliper
  150
- Disassembling the Front Brake Caliper
  150
- Removing the Front Brake Caliper
  150
- Installing the Front Brake Caliper
  151
- Assembling the Front Brake Master Cylinder
  152
- Checking the Front Brake Master Cylinder
  152
- Removing the Front Brake Master Cylinder
  152
- Installing the Front Brake Master Cylinder
  153
- Rear Brake
  155
- Checking the Rear Brake Disc
  159
- Introduction
  159
- Replacing the Rear Brake Pads
  159
- Assembling the Rear Brake Caliper
  161
- Checking the Rear Brake Caliper
  161
- Disassembling the Rear Brake Caliper
  161
- Removing the Rear Brake Caliper
  161
- Installing the Rear Brake Caliper
  162
- Removing the Rear Brake Master Cylinder
  162
- Assembling the Rear Brake Master Cylinder
  163
- Checking the Rear Brake Master Cylinder
  163
- Installing the Rear Brake Master Cylinder
  164
- Checking the Handlebar
  166
- Installing the Handlebar
  166
- Removing the Handlebar
  166
- Front Fork
  171
- Disassembling the Front Fork Legs
  173
- Removing the Front Fork Legs
  173
- Checking the Front Fork Legs
  174
- Assembling the Front Fork Legs
  175
- Installing the Front Fork Legs
  181
- Steering Head
  184
- Checking the Steering Head
  185
- Installing the Steering Head
  185
- Removing the Lower Bracket
  185
- Rear Shock Absorber Assembly
  188
- Checking the Rear Shock Absorber Assembly
  191
- Disposing of a Rear Shock Absorber
  191
- Handling the Rear Shock Absorber
  191
- Removing the Rear Shock Absorber Assembly
  191
- Checking the Connecting Arm and Relay Arm
  192
- Installing the Rear Shock Absorber Assembly
  192
- Installing the Relay Arm
  192
- Swingarm
  194
- Checking the Swingarm
  195
- Installing the Swingarm
  195
- Removing the Swingarm
  195
- Chain Drive
  197
- Checking the Drive Chain
  198
- Removing the Drive Chain
  198
- Checking the Drive Sprocket
  199
- Checking the Rear Wheel Sprocket
  199
- Installing the Drive Chain
  199
Engine

201
- Engine Oil Lubrication Chart
  203
- Lubrication System Chart and Diagrams
  203
- Lubrication Diagrams
  204
- Engine Removal
  208
- Installing the Engine
  212
- Removing the Engine
  212
- Installing the Exhaust Pipe and Muffler
  213
- Camshaft
  215
- Removing the Camshaft
  217
- Checking the Camshaft
  218
- Checking the Decompression System
  219
- Checking the Timing Chain and Camshaft Sprocket
  219
- Checking the Timing Chain Tensioners
  219
- Installing the Camshafts
  219
- Cylinder Head
  222
- Checking the Cylinder Head
  224
- Checking the Timing Chain Guide (Intake Side)
  224
- Installing the Cylinder Head
  224
- Removing the Cylinder Head
  224
- Valves and Valve Springs
  227
- Removing the Valves
  228
- Checking the Valves and Valve Guides
  229
- Checking the Valve Seats
  230
- Checking the Valve Springs
  231
- Checking the Valve Lifters
  232
- Installing the Valves
  232
- Cylinder and Piston
  234
- Checking the Cylinder and Piston
  235
- Removing the Piston
  235
- Checking the Piston Rings
  236
- Checking the Piston Pin
  237
- Installing the Piston and Cylinder
  237
- Generator
  239
- Checking the Generator
  240
- Checking the Woodruff Key
  240
- Installing the Generator
  240
- Removing the Generator
  240
- Starter Clutch
  242
- Checking the Starter Clutch
  243
- Assembling the Starter Motor
  246
- Checking the Starter Motor
  246
- Electric Starter
  246
- Checking the Clutch Boss
  251
- Checking the Clutch Housing
  251
- Checking the Clutch Plates
  251
- Checking the Clutch Springs
  251
- Checking the Friction Plates
  251
- Removing the Clutch
  251
- Checking the Pressure Plate
  252
- Checking the Primary Drive Gear
  252
- Checking the Primary Driven Gear
  252
- Checking the Push Lever Shaft
  252
- Checking the Push Rods
  252
- Installing the Clutch
  252
- Shift Shaft
  256
- Checking the Shift Shaft
  257
- Checking the Stopper Lever
  257
- Installing the Shift Shaft
  257
- Removing the Segment
  257
- Oil Pump
  260
- Assembling the Oil Pump
  262
- Checking the Oil Pump
  262
- Removing the Balancer
  262
- Installing the Oil Pump
  263
- Crankcase
  265
- Checking the Crankcase
  267
- Checking the Timing Chain Guide (Exhaust Side)
  267
- Disassembling the Crankcase
  267
- Assembling the Crankcase
  268
- Crankshaft and Balancer Shaft
  269
- Checking the Crankshaft
  270
- Removing the Crankshaft
  270
- Installing the Crankshaft
  271
- Transmission
  272
- Checking the Shift Drum Assembly
  273
- Checking the Shift Forks
  273
- Checking the Transmission
  273
- Removing the Transmission
  273
- Installing the Transmission
  274
Cooling System

277
- Cooling System Diagrams
  278
- Radiator
  279
- Checking the Radiator
  281
- Installing the Radiator
  281
- Water Pump
  283
- Assembling the Water Pump
  284
- Checking the Water Pump
  284
- Disassembling the Water Pump
  284
Fuel System

287
- Checking the Fuel Pump Body
  289
- Checking the Fuel Pump Operation
  289
- Fuel Tank
  289
- Removing the Fuel Pump
  289
- Removing the Fuel Tank
  289
- Installing the Fuel Pump
  290
- Installing the Fuel Tank
  290
- Throttle Body
  291
- Checking the Fuel Pressure
  294
- Checking the Injector
  294
- Checking the Throttle Body
  294
- Adjusting the Throttle Position Sensor
  295
Electrical System

297
- Circuit Diagram
  300
- Ignition System
  300
- Troubleshooting
  302
- Circuit Diagram
  304
- Electric Starting System
  304
- Starting Circuit Cut-Off System Operation
  306
- Troubleshooting
  308
- Charging System
  310
- Circuit Diagram
  310
- Troubleshooting
  312
- Circuit Diagram
  314
- Signaling System
  314
- Troubleshooting
  316
- Circuit Diagram
  318
- Lighting System
  318
- Troubleshooting
  320
- Circuit Diagram
  322
- Cooling System
  322
- Troubleshooting
  324
- Circuit Diagram
  326
- Fuel Injection System
  326
- Ecu Self-Diagnostic Function
  328
- Troubleshooting Method
  329
- Connecting the Yamaha Diagnostic Tool
  330
- Yamaha Diagnostic Tool
  330
- Troubleshooting Details (Fault Code)
  332
- Circuit Diagram
  352
- Fuel Pump System
  352
- Troubleshooting
  354
- Electrical Components
  355
- Checking the Switches
  356
- Checking the Bulbs and Bulb Sockets
  358
- Checking the Fuses
  358
- Checking and Charging the Battery
  359
- Checking the Relays
  361
- Checking the Relay Unit (Diode)
  363
- Checking the Ignition Coil
  364
- Checking the Ignition Spark Gap
  364
- Checking the Spark Plug Cap
  364
- Checking the Crankshaft Position Sensor
  365
- Checking the Lean Angle Sensor
  366
- Checking the Rectifier/Regulator
  366
- Checking the Starter Motor Operation
  366
- Checking the Stator Coil
  366
- Checking the Fuel Sender
  367
- Checking the Resistor
  367
- Checking the Speed Sensor
  367
- Checking the Coolant Temperature Sensor
  368
- Checking the Radiator Fan Motor
  368
- Checking the Intake Air Temperature Sensor
  369
- Checking the Throttle Position Sensor Input Voltage
  369
- Checking the Gear Position Switch
  370
- Checking the Injector
  370
Troubleshooting

371
Tuning

387
- Chassis
  388
- Drive and Rear Wheel Sprockets Setting Parts
  388
- Front Fork Setting
  388
- Selection of the Secondary Reduction Ratio (Sprocket)
  388
- Tire Pressure
  388
- Change in Amount and Characteristics of Fork Oil
  389
- Setting of Spring after Replacement
  389
- Choosing Set Length
  390
- Front Fork Setting Parts
  390
- Rear Suspension Setting
  390
- Setting of Spring after Replacement
  391
- Rear Shock Absorber Setting Parts
  392
- Suspension Setting (Front Fork)
  393
- Suspension Setting (Rear Shock Absorber)
  394

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