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