WR450FR
Page
By Yamaha Motor Corporation, U.S.A 1st Edition, October
WR450FR
LIT-11626-16-43
Introduction
Page
Always Maintain Your Machine in Proper Working Order
Always Wear Protective Apparel
Park the Machine Carefully Turn OFF the Engine
Gasoline can Cause Injury
Properly Secure the Machine Before Transporting IT
Weights of machines without fuel
M. Machine Weights
Finding the Required
Particularly Important Information
Manual Format
HOW to Read Descriptions
GEN Spec Info Insp ENG ADJ
Memo
Index
Chapter Regular Inspection Adjustments
Front Wheel and Rear Wheel Front Brake and Rear Brake
SEAT, Fuel Tank Side Covers
TPS Throttle Position Sensor
Electrical Components
Description
Description Info
Model Label
Machine Identification
Vehicle Identification Number
Engine Serial Number
Important Information
Preparation for Removal and Disassembly
Bearings and OIL Seals
ALL Replacement Parts
Lock WASHERS/PLATES and Cotter Pins
GASKETS, OIL Seals and O-RINGS
Circlips
Checking of Connection
Special Tools
Part number Tool name/How to use Illustration
GEN Info
ACC-QUICK-GS-KT
Control Functions
Main Switch
Main switch indicator light
Start Switch
Throttle Grip
Clutch Lever
Shift Pedal
Kickstarter
HOT Starter Lever
Rear Brake Pedal
Fuel Cock
Cold Starter Knob
Nipple Wrench
Lights Switch
Valve Joint
Spark Plug Wrench
Fuel
Starting and BREAK-IN
AIR Filter Maintenance
Starting a Cold Engine
Do not warm up the engine for extended periods of time
Restarting an engine after a fall
Starting a Warm Engine
Engine fails to start
PISTON, RING, VALVES, Camshafts and Gears
BREAK-IN Procedures
Cylinder and Crankshaft
About one hour of break-in operation is necessary
TORQUE-CHECK Points
Cleaning
Cleaning and Storage
Storage
5TJ4 CDN, AUS, NZ, ZA
General Specifications
FCR MX39
CDI
Engine
Maintenance Specifications
Seat Width
7083 ~ 0.7087 7075
Spec
USA CDN, AUS, NZ
Spec
Standard Lubrication chart
Part to be tightened Thread size ’ty Tightening torque
Oil strainer frame
USA, CDN Europe AUS, NZ, ZA
Chassis
DID520VM/DAIDO
Handle crown and outer tube
Rear wheel axle and nut
M4 ⋅
5TA-00/DENSO
Electrical
ACM33221 M06/MATSUSHITA
Mkg Ftlb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 16 mm 130
General Torque Specifications
Definition of Units
Torque
Lubrication Diagrams
Spec
Cable Routing Diagram
Spec
Spec
Spec
Spec
Spec
Insp ADJ
Maintenance Intervals
Shift FORK, Shift CAM, Guide BAR
Marked For USA
General Inspection and Maintenance
PRE-OPERATION Inspection and Maintenance
Coolant Level Inspection
Coolant Replacement
Do not remove the radiator cap when the engine is hot
Engine
Coolant Replacement
Fill Radiator Engine To specified level
Radiator CAP Opening Pressure Inspection
Radiator CAP Inspection
Radiator cap opening pressure 110 kPa 1.1 kg/cm2, 15.6 psi
Cooling System Inspection
Cooling System Inspection
Standard pressure KPa 1.8 kg/cm2, 25.6 psi
Throttle Cable Adjustment
Clutch Adjustment
Hot starter lever free play a 3 ~ 6 mm 0.12 ~ 0.24
HOT Starter Lever Adjustment
Hot starter lever free play adjustment steps
Throttle Lubrication
AIR Filter Cleaning
AIR Filter Cleaning
Insp ADJ
Engine OIL Level Inspection
Engine OIL Level Inspection
API Standard
When the oil tank is empty, never start the engine
Recommended oil
Recommended engine oil classi- fication
Engine OIL Replacement
Engine OIL Replacement
Oil filter cover 10 Nm 1.0 m kg, 7.2 ft lb
Replacement steps
Pilot Screw Adjustment
Pilot Screw Adjustment
Adjustment steps
Idle Speed Adjustment
Valve Clearance Adjustment
Valve Clearance Adjustment
Mm increments
Pad range Pad Availability Increments 20 mm
40 mm
Example
Last digit of pad Rounded value
Bolt camshaft cap 10 Nm 1.0 m kg, 7.2 ft lb
Insp ADJ
Exhaust
Intake
Spark Arrester Cleaning For USA
Chassis
CHASSIS/BRAKE System AIR Bleeding
Brake System AIR Bleeding
Locknut Nm 0.5 m kg, 3.6 ft lb
Front Brake Adjustment
Front Brake Adjustment
Brake lever position adjustment steps
Front Brake PAD Inspection and Replacement
Rear Brake Adjustment
Do not reuse the drained brake fluid
Front Brake PAD Inspection and Replacement
Bleed screw Nm 0.6 m kg, 4.3 ft lb
Brake pad thickness a Standard Limit Mm 0.25 Mm 0.04
Rear Brake PAD Inspection and Replacement
Rear Brake PAD Inspection and Replacement
Pad pin plug Nm 0.3 m kg, 2.2 ft lb
Pad pin 18 Nm 1.8 m kg, 13 ft lb
Brake Fluid Level Inspection
Rear Brake PAD Insulator Inspection
Drive chain length 10 links Limit 150.1 mm 5.91
Sprockets INSPECTION/DRIVE Chain Inspection
Sprockets Inspection
Drive Chain Inspection
Drive Chain Inspection
Drive chain slack 40 ~ 50 mm 1.6 ~ 2.0
Drive Chain Slack Adjustment
Drive Chain Slack Adjustment
Drive chain slack adjustment steps
Front Fork Inspection
Front Fork OIL Seal and Dust Seal Cleaning
Axle nut 125 Nm 12.5 m kg, 90 ft lb
Locknut 16 Nm 1.6 m kg, 11 ft lb
Front Fork Internal Pressure Relieving
Front Fork Rebound Damping Force Adjustment
Standard position 10 clicks out Clicks out
Front Fork Compression Damping Force Adjustment
Rear Shock Absorber Inspection
Rear Shock Absorber Inspection
246 mm 9.69 240.5 ~ 258.5 mm
Rear Shock Absorber Spring Preload Adjustment
47 ~ 10.18
Standard position About 9 clicks out *About 10 clicks out
Rear Shock Absorber Rebound Damping Force Adjustment
Standard position About 6 clicks out *About 13 clicks out
Rear Shock Absorber LOW Compression Damping Force Adjustment
EC36d000
Wheel Inspection
Tire Pressure Check
Standard tire pressure KPa 1.0 kgf/cm2, 15 psi
Spokes Inspection and Tightening
Ring nut wrench YU-33975/90890-01403
Steering Head Inspection and Adjustment
Steering Head Inspection Adjustment
Steering ring nut adjustment steps
Cautio N
Lubrication
Lubrication
Spark plug gap ~ 0.8 mm 0.028 ~ 0.031
ELECTRICAL/SPARK Plug Inspection
Electrical
Spark Plug Inspection
Ignition Timing Check
Ignition Timing Check
First AID in Case of Bodily Contact External
Battery Inspection and Charging
Battery Inspection and Charging
Keep Batteries and Electrolyte OUT of Reach of Children
Measurement steps
Example
Do not quick charge a battery
Insp ADJ
Charging method using a variable voltage charger
Charging method using a constant voltage charger
Fuse Inspection
Fuse Inspection
First, connect the positive lead 1, then the negative lead
Recommended lubricant Lithium soap base grease
Items Amperage ’ty Rating
Replacing the Headlight Bulbs
Replacing the Headlight Bulbs
Adjusting the Headlight Beams
Adjusting the Headlight Beams
SEAT, Fuel Tank and Side Covers Removal
SEAT, Fuel Tank and Side Covers
Side cover
Removal Points
Exhaust Pipe Silencer Removal
Exhaust Pipe and Silencer
Exhaust pipe and silencer
Assembly and Installation Exhaust pipe and silencer
Radiator Removal
Radiator
Handling Note
Assembly and Installation Radiator
Radiator
Install Radiator breather hose Radiator right
Carburetor Removal
Carburetor
Carburetor Disassembly
Carburetor Disassembly
ENG
Carburetor
Pilot screw
Standard clip position No.4 Groove
Needle valve
Throttle valve
Jet needle
Float
Measurement and adjustment steps
Starter plunger
Accelerator pump
Assembly and Installation Carburetor
Air cut valve
ENG
ENG
Pilot screw 4 turns out example 2 turns out example
ENG
Throttle valve height Mm 0.122
Accelerator pump timing adjustment Adjustment steps
Carburetor installation
Carburetor ENG
Tighten Screw air cleaner joint
Cylinder Head Cover
Camshafts
Cylinder Head Cover Removal
Camshafts Removal
Camshaft
Runout camshaft Less than 0.03 mm 0.0012
Bolt camshaft cap 10 Nm 1.0 m kg, 7.2 ft lb
Timing chain tensioner
Assembly and Installation
Installation steps
Decompression system
Bolt camshaft cap
CA U TI on
Bolt timing chain tensioner
Camshafts ENG
Tensioner cap bolt
Cylinder Head Removal
Cylinder Head
Cylinder head
Bolts cylinder head 1st 30 Nm 3.0 m kg, 22 ft lb
Final
Bolts cylinder head
2nd
20 Nm 2.0 m kg, 14 ft lb
Valves and Valve Springs Removal
Valves and Valve Springs
Valve spring compressor YM-4019/90890-04019
Valve
ENG
Runout limit 01 mm 0.0004
Lapping steps
Valve spring
Black
Combination of cylinder head and valve lifter
Combination Cylinder head mark Valve lifter mark Color
Yellow
CA UT ION
Cylinder and Piston Removal
Cylinder and Piston
Cylinder and piston
Piston
Piston pin puller YU-1304/90890-01304
Do not use a hammer to drive the piston pin out Piston ring
Piston size P Standard
Cylinder bore C 95.00 ~ 95.01 mm 7402 ~ 3.7406
05 mm 0.002
2nd step
End gap Standard Limit
2nd ring 020 ~ 0.055 mm 12 mm 0008 ~ 0.0022
20 ~ 0.50 mm 01 ~ 0.02
Inside diameter piston 18.004 ~ 18.015 mm 0.7088 ~ 0.7093
Piston pin
Cylinder
Clutch Removal
Clutch
ENG
Primary driven gear
Clutch housing and boss
Clutch boss
Clutch holding tool YM-91042/90890-04086
Push rod
Friction plate
Clutch plate
Warp limit Mm 0.004 Push lever
Clutch
Assembly and Installation Push lever
ENG
Install Clutch spring Bolt clutch spring
OIL FILTER, Water Pump and Crankcase Cover Right
OIL FILTER, Water Pump and Crankcase Cover Right
OIL FILTER, Water Pump Crankcase Cover Right Removal
ENG
Oil seal
Impeller shaft
Bearing
Crankcase cover right
Kick crank
Water pump housing
Oil filter
Balancer Removal
Balancer
Balancer
Balancer drive gear and balancer driven gear
Balancer, balancer drive gear and balancer driven gear
OIL Pump
OIL Pump Removal and DIS Assembly
ENG
Oil pump
Assembly and Installation Oil pump
Bolt oil pump assembly L = 25 mm 0.98
Kick Axle and Shift Shaft Removal
Kick Axle and Shift Shaft
ENG
Kick axle and ratchet wheel
Kick axle assembly
Shift guide and shift lever assembly
Segment
Shift shaft
Assembly and Installation Segment
Stopper lever
Install Torsion spring Stopper lever Bolt stopper lever
EC4C5301
Kick idle gear
AC Magneto and Stator Removal
AC Magneto and Starter Clutch
ENG
Woodruff key
Rotor
Rotor puller YM-04141/90890-04141
AC magneto
Starter clutch
Assembly and Installation AC magneto and starter clutch
Quick gasket ACC-QUICK-GS-KT Yamaha Bond No 90890-85505
Install Bolt starter clutch
Install Engine guard Clamp Bolt engine guard front
Engine Removal
Engine Removal
ENG
ENG
Engine removal
Drive sprocket
Brake pedal
Assembly and Installation Engine installation
Install Ring 1 New Dowel pin Oil hose Bolt oil hose
Crankcase Separation
Crankcase and Crankshaft
ENG
Crankcase Bearing Removal
Crankcase Bearing
Separation steps
Crankcase
Crankcase separating tool YU-1135-A/90890-01135
Crankshaft
Timing chain and timing chain guide
Oil delivery pipe
Assembly and Installation Crankshaft bearing
Quick gasket ACC-QUICK-GS-KT Yamaha Bond No
Do not use a hammer to drive in the crank- shaft
Bolt crankcase
TRANSMISSION, Shift CAM and Shift Fork
TRANSMISSION, Shift CAM and Shift Fork
TRANSMISSION, Shift CAM Shift Fork Removal
Gears
Shift fork, shaft cam and transmission
Shift fork, shift cam and segment
Assembly and Installation Transmission
ENG
ENG
Front Wheel Removal
Front Wheel and Rear Wheel Chas
Front Wheel and Rear Wheel
Front Wheel
Rear Wheel Removal
Rear Wheel
Wheel bearing if necessary
Rear wheel
Wheel
Brake disc
Wheel axle
Wheel axle bending limit 0.5 mm 0.020
Do not attempt to straighten a bent axle
Front wheel
Caacuhtutionng
105 Nm 10.5 m · kg, 75 ft · lb
Tighten Bolt axle holder
Tighten the nuts in stage, using a crisscross pattern
Front Wheel and Rear Wheel Chas
Adjust Drive chain slack a
Front Brake Removal
Front Brake and Rear Brake Chas
Front Brake and Rear Brake
Front Brake
Rear Brake Removal
Rear Brake
Caliper Disassembly
Caliper Disassembly
Master Cylinder Disas Sembly
Master Cylinder Disassembly
Caliper piston
Brake fluid
Master cylinder
Piston seal kit
Use only new brake fluid
Brake hose
Caliper
Front caliper
Always use new piston seals and dust seals
Rear caliper
Always use new copper washers
Master cylinder kit
Front master cylinder
Rear master cylinder
Caauchtutionng
Front brake hose
Cauachttuniong
Install Brake hose holder Screw brake hose holder
Rear Diaphragm Master cylinder cap Bolt master cylinder cap
Front Fork
Front Fork Chas
Front Fork Removal
Front Fork Disassembly
Front Fork Disassembly
Cap bolt
Damper rod
Inner tube
Take care not to scratch the inner tube
Oil seal removal steps
Outer tube
Base valve
Fork spring
Inner tube bending limit 0.2 mm 0.008
Assembly and Installation Front fork assembly
Front Fork Chas
Fork seal driver YM-01442/90890-01442
Recommended oil Suspension oil
Front Fork Chas
Front Fork Chas
Front fork top end standard a Zero mm Zero
Installation
Tighten Pinch bolt handle crown
Handlebar
Handlebar Chas
Handlebar Removal
Handlebar
Grip
Assembly and Installation Handlebar
Install Cover grip cap Cover throttle cable cap
Hot starter lever holder Bolt hot starter lever holder
Handlebar Chas
Steering
Steering Chas
Steering Removal
Steering Chas
Ball race
Ring nut
Bearing lower
Take care not to damage the steering shaft thread
Under bracket
Bearing and ball race
Install Plain washer Ring nut
Install Trip meter Bolt trip meter
Swingarm
Swingarm Chas
Swingarm Removal
Swingarm Disassembly
Swingarm Disassembly
Relay arm
Swingarm
Bearing and oil seal
Connecting rod
Installed depth of bearings a 5 mm 0.20 Swingarm
Installed depth of bearings a 5 mm 0.20
80 Nm 8.0 m · kg, 58 ft · lb
Tighten Nut relay arm
Bolt support cover r= 10 mm 0.39
Rear Shock Absorber
Rear Shock Absorber Chas
Rear Shock Absorber Removal
Rear Shock Absorber Chas
Rear Shock Absorber Chas
EC586000
Rear shock absorber
Spring rear shock absorber
Installed depth of the bearing a 4 mm 0.16
Adjustment
Spring length installed a Standard Extent
Bolt rear frame lower
Rear Shock Absorber Chas
Wiring Diagram
Electrical Components and Wiring Diagram
Color Code
Function of Component
MAP-CONTROLLED CDI Unit
Inspection Steps
Ignition System
Engine Stop Button Inspection
Ignition System Elec +
Spark GAP Test
COUPLERS, Leads and Ignition Coil Connection Inspection
OFF
Main Switch Inspection
Ignition Coil Inspection
AC Magneto Inspection
Neutral Switch Inspection
CDI Unit Inspection
Starting Circuit CUT-OFF System Operation
Electric Starting System
Inspection Steps
Tor position
Couplers and Leads Connection Inspection
Starter Motor Operation
Starting Circuit CUT-OFF Relay Inspection
Starter Relay Inspection
Clutch Switch Inspection
Pull Free
Diode Inspection
Remove the diode from wire harness
Start Switch Inspection
Electric Starting System Elec +
Starter Motor Removal
Starter Motor
Starter Motor Disassem BLY
Elec
Min. commutator diameter 16.6 mm 0.65
Inspection and Repair
Mica undercut 1.5 mm 0.06
Be careful not to damage the brush during installation
Assembly
Min. brush length Mm 0.14
New
Charging System
000 r/min
Charging Voltage Inspection
Tester + lead → Red lead Tester lead → Black lead
DCV-20
TPS Throttle Position Sensor System
TPS Coil Inspection
TPS Throttle Position Sensor System Elec +
Tester + lead → Yellow lead Tester lead → Black lead
TPS Replacement and Adjustment
DCV
58 ~ 0.78
Tester + lead → Blue lead 1 Tester lead → Black/Blue lead
TPS Input Voltage Inspection
~ 6 DCV-20
Lighting System
RECTIFIER/REGULATOR Inspection
Lights Switch Inspection
Tester + lead → Yellow lead Tester lead → Blue lead
No continuous while being → Replace
Carburetor setting
Setting
Humidity
Effects of the setting parts on the throttle valve opening
Setting T U N
Main system
Effects of changing the main jet reference
Main jet adjustment
Pilot system
Standard main jet #150 #160
Effects of adjusting the pilot screw reference
Pilot screw adjustment
Standard pilot Screw position Example
Standard pilot jet #45 #48
Pilot jet adjustment
Effects of adjusting the pilot jet reference
Jet needle groove position adjustment
Effects of changing the jet needle reference
Jet needle adjustment
Standard jet needle
Obdut Obduq
#DUW
STD
#DUS
#DUV
Examples of carburetor setting depending on symptom
Standard secondary reduction ratio 50/14
Selection of the secondary reduction ratio Sprocket
Size Part number
5NG-17460-00
9383E-14215
For CDN, EUROPE, AUS, NZ and ZA
Change in level and characteristics of fork oil
Front fork setting
Setting of spring after replacement
Spring preload adjustment
Setting
Rate
Part Number
Spring
Mark
Choosing set length
Rear suspension setting
Standard figure 90 ~ 100 mm 3.5 ~ 3.9
EC72G001
Setting
Adjustment b
Rear shock absorber setting parts
Spring Free Extent
Suspension setting
One passenger is astride seat
Printed on Recycled Paper Shingai Iwata Shizuoka Japan