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• Page 1
  Read this manual carefully before operating this vehicle. OWNER’S MANUAL WR450F 1DX-28199-E1…
• Page 2
  EAU46090 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
• Page 3
  Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your WR450F. The Owner’s Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.

• Page 4: Important Manual Information

  IMPORTANT MANUAL INFORMATION EAU10133 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

• Page 5
  IMPORTANT MANUAL INFORMATION EAU10200 WR450F OWNER’S MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st edition, July 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

• Page 6: Table Of Contents

  TABLE OF CONTENTS SAFETY INFORMATION ….1-1 Ignition circuit cut-off system ..3-19 Checking the throttle grip free play ……….6-17 DESCRIPTION ……..2-1 FOR YOUR SAFETY – Valve clearance ……6-18 Left view ………. 2-1 PRE-OPERATION CHECKS ….. 4-1 Tires ……….

• Page 7
  TABLE OF CONTENTS Checking the steering ….6-30 Checking the wheel bearings ..6-30 Battery ………. 6-30 Replacing the fuse ……6-32 Replacing the headlight bulb ..6-32 Tail/brake light ……6-34 Replacing a turn signal light bulb ……….. 6-34 Replacing the license plate light bulb ……..

• Page 8: Safety Information

  SAFETY INFORMATION EAU53004 Take a training course. Beginners replaced with non-specified com- should receive training from a cer- ponents, the vehicle will no longer tified instructor. Contact an autho- meet the regulations. Be a Responsible Owner  rized motorcycle dealer to find out Watch carefully for other vehicles As the vehicle’s owner, you are respon- about the training courses nearest…

• Page 9
  SAFETY INFORMATION motorist’s blind spot. • Always obey the speed limit and could contribute to an impairment • Never maintain a motorcycle never travel faster than warrant- of vision that could delay seeing a without proper knowledge. Con- ed by road and traffic conditions. hazard.
• Page 10
  Yamaha accessories, which are avail- When loading within this weight limit, ports. able only from a Yamaha dealer, have keep the following in mind:  Do not run engine outdoors where been designed, tested, and approved …

• Page 11: Specifications

  SAFETY INFORMATION mended by Yamaha, even if sold and sion travel, steering travel or con- electric failure could result, which installed by a Yamaha dealer. trol operation, or obscure lights or could cause a dangerous loss of reflectors. lights or engine power.

• Page 12
  SAFETY INFORMATION tie-downs or suitable straps that are attached to solid parts of the motorcycle, such as the frame or upper front fork triple clamp (and not, for example, to rubber-mount- ed handlebars or turn signals, or parts that could break). Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport.

• Page 13: Description

  DESCRIPTION EAU10410 Left view 1, 2 4, 5 6 1. Front fork compression damping force adjusting screw (page 3-14) 8. Shift pedal (page 3-8) 2. Bleed screw (page 3-15) 9. Engine oil filler cap (page 6-8) 3. Starter knob (page 3-12) 10.Engine oil drain bolt (oil tank) (page 6-8) 4.

• Page 14: Right View

  DESCRIPTION EAU10420 Right view 1, 2 1. Shock absorber assembly compression damping force adjusting 7. Coolant drain bolt (page 6-13) screw (for slow compression damping) (page 3-16) 8. Brake pedal (page 3-9) 2. Shock absorber assembly compression damping force adjusting nut 9.

• Page 15: Controls And Instruments

  DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-8) 8. Throttle grip (page 6-17) 2. Left handlebar switches (page 3-7) 3. Multi-function display (page 3-2) 4. Main switch (page 3-1) 5. Front brake fluid reservoir (page 6-23) 6. Right handlebar switches (page 3-7) 7.

• Page 16: Instrument And Control Functions

  INSTRUMENT AND CONTROL FUNCTIONS EAU10451 EAU52471 EAU49392 Main switch Indicator lights and warning All electrical systems are off. lights EWA16130 WARNING Never push the main switch to “OFF” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident.

• Page 17: Multi-Function Display

  “ON”, or if the warning light remains This warning light comes on when the operator and increase the risk of an on, have a Yamaha dealer check the fuel level drops below approximately accident. electrical circuit.

• Page 18
  INSTRUMENT AND CONTROL FUNCTIONS last set to zero) ton until the display changes after  a clock the main switch is pushed to “ON”. Measurement mode: Basic mode  a speedometer  a distance-compensation tripme- Odometer and tripmeter modes ter (which shows the accumulated Push the “SLCT 2”…
• Page 19
  INSTRUMENT AND CONTROL FUNCTIONS push either select button to set the Changing from the basic mode to hours. the measurement mode 3. Push the “RST” button, and the With the odometer selected, push the minute digits will start flashing. “SLCT 1” button and “SLCT 2” button 4.
• Page 20
  INSTRUMENT AND CONTROL FUNCTIONS Auto start 1. Push the “SLCT 1” button for at Starting measurement consists of the least two seconds to set the auto following two starts, either of which can start. be selected.  Manual start Starting measurement by the rider When the stopwatch is set to auto start, himself operating the button.
• Page 21
  Resetting the distance-compensation specified. For further information con- tripmeter cerning the use of this meter, please 1. Check that the stopwatch mea- consult your nearby Yamaha dealer. surement is in operation. Calibrate the distance-compensation 2. Reset the distance-compensation tripmeter as follows.

• Page 22: Handlebar Switches

  INSTRUMENT AND CONTROL FUNCTIONS EAU1234B EAU12400 with the starter. See page 5-1 for start- Handlebar switches Dimmer switch “ ” ing instructions prior to starting the en- Set this switch to “ ” for the high gine. Left beam and to “ ”…

• Page 23: Clutch Lever

  INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12871 EAU41264 Clutch lever Shift pedal Brake lever The brake lever is located on the right side of the handlebar. To apply the front brake, pull the lever toward the throttle grip. 1. Clutch lever 1.

• Page 24: Brake Pedal

  INSTRUMENT AND CONTROL FUNCTIONS 3. While holding the lever pushed EAU12941 EAU13182 Brake pedal Fuel tank cap away from the throttle grip, turn the adjusting bolt in direction (a) to in- crease the distance, and in direc- tion (b) to decrease it. Distance between the brake lever and the throttle grip: Minimum (shortest):…

• Page 25: Fuel

  Gasoline is poisonous and can Your Yamaha engine has been de- heat from the engine or the sun cause injury or death. Handle gaso- signed to use premium unleaded gaso- can cause fuel to spill out of the line with care.

• Page 26: Fuel Tank Breather Hose

  INSTRUMENT AND CONTROL FUNCTIONS spark plug life and reduce maintenance EAU41360 EAU13433 Fuel tank breather hose Catalytic converter costs. This model is equipped with a catalytic converter in the exhaust system. EWA10862 WARNING The exhaust system is hot after op- eration.

• Page 27: Starter Knob

  INSTRUMENT AND CONTROL FUNCTIONS converter. EAU53230 EAU13650 Starter knob Kickstarter 1. Starter knob/idle adjusting screw 1. Kickstarter lever Starting a cold engine requires a richer To start the engine, fold out the kick- air-fuel mixture, which is supplied by starter lever, move it down lightly with the starter.

• Page 28: Steering Lock

  INSTRUMENT AND CONTROL FUNCTIONS EAU53100 rection. EAU53200 Steering lock Seat 3. Remove the key. WARNING! Never ride with the key inserted To remove the seat into the steering lock, which Remove the bolts, and then slide the may result in loss of control and seat to the rear and pull upward.

• Page 29: Install Seat

  INSTRUMENT AND CONTROL FUNCTIONS To install the seat EAU52450 Adjusting the front fork 1. Fit the slot in the seat onto the pro- EWA10180 jection on the fuel tank. WARNING Always adjust both fork legs equal- ly, otherwise poor handling and loss of stability may result.

• Page 30: Front Fork Bleeding

  INSTRUMENT AND CONTROL FUNCTIONS each fork leg in direction (b). range. To obtain a precise adjustment, EAU14793 Front fork bleeding it would be advisable to check the num- EWA10200 ber of clicks of each damping force ad- WARNING justing mechanism and to modify the Always bleed both fork legs, other- specifications as necessary.

• Page 31: Adjusting The Shock Absorber Assembly

  Maximum (hard): Spring preload Distance A = 222 mm (8.74 in) Spring preload adjustment should be made by a Yamaha dealer, since this Rebound damping force service requires special tools and tech- To increase the rebound damping force nical skills. The specified settings are and thereby harden the rebound damp- listed below.

• Page 32
  INSTRUMENT AND CONTROL FUNCTIONS sion damping force and thereby soften sion damping, turn the adjusting screw the compression damping, turn the ad- in direction (a). To decrease the com- justing bolt in direction (b). pression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b).

• Page 33: Sidestand

  INSTRUMENT AND CONTROL FUNCTIONS visable to check the actual total number absorber assembly to a Yamaha EAU15305 Sidestand of clicks or turns of each damping force dealer for any service. The sidestand is located on the left side adjusting mechanism. This adjustment of the frame.

• Page 34: Ignition Circuit Cut-Off System

  INSTRUMENT AND CONTROL FUNCTIONS Yamaha dealer repair it if it does not EAU52861 Ignition circuit cut-off system function properly. The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions. …

• Page 35
  INSTRUMENT AND CONTROL FUNCTIONS WARNING With the engine turned off: 1. Move the sidestand down. If a malfunction is noted, have a Yamaha 2. Make sure that the engine stop switch is set to “ ”. dealer check the system before riding.

• Page 36: For Your Safety — Pre-Operation Checks

  • If necessary, add recommended coolant to specified level. 6-12 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary.

• Page 37
  • Make sure that operation is smooth. • Check throttle grip free play. Throttle grip 6-17, 6-27 • If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-27 •…
• Page 38
  • Tighten if necessary. Instruments, lights, signals • Check operation. — and switches • Correct if necessary. • Check operation of ignition circuit cut-off system. Sidestand switch 3-18 • If system is not working correctly, have Yamaha dealer check vehicle.

• Page 39: Operation And Important Riding Points

   a lean angle sensor to stop the en- celerate hard when the engine is understand, ask your Yamaha dealer. gine in case of a turnover. In this cold! EWA10271 case, the multi-function display in-…

• Page 40
  Use the kickstarter when the ambient light should come on. If not, ask a temperature is below 10 C (50 F) or Yamaha dealer to check the elec- when at high altitude. trical circuit. 5. When the engine is warm, turn the 3.

• Page 41: Starting A Warm Engine

  OPERATION AND IMPORTANT RIDING POINTS EAU52971 EAU16671 Starting a warm engine Shifting If the engine fails to start, push the main Follow the same procedure as for start- switch to “OFF” and give the kickstarter ing a cold engine with the exception 10 to 20 slow kicks at full throttle in or- that the starter is not required when the der to clear the engine of the rich air-fu-…

• Page 42: Tips For Reducing Fuel Consumption

  Do not rev the engine while shifting you are not familiar with vehicle ser-  Always use the clutch while down, and avoid high engine vice, have a Yamaha dealer perform changing gears to avoid damag- speeds with no load on the engine. service. …

• Page 43: Parking

  EWA10311 for about 10 to 15 more minutes. period, immediately have a WARNING The motorcycle will now be ready Yamaha dealer check the vehi-  Since the engine and exhaust to ride normally. cle. system can become very hot,…

• Page 44: Periodic Maintenance And Adjustment

  – possibly leading to pending on the weather, terrain, geo- that is certified (if applicable). Yamaha death. See page 1-2 for more in- graphical location, and individual use, dealers are trained and equipped to…

• Page 45: Owner’s Tool Kit

  If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.

• Page 46: Periodic Maintenance Chart For The Emission Control System

  From 7000 km (4200 mi) or 9 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 3 months.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

• Page 47: General Maintenance And Lubrication Chart

  PERIODIC MAINTENANCE AND ADJUSTMENT EAU52581 General maintenance and lubrication chart ODOMETER INITIAL READINGS ANNUAL 3000 km 5000 km ITEM CHECKS AND MAINTENANCE JOBS 1000 km CHECK (1800 mi) (3000 mi) (600 mi) or or 3 or 6 1 month months months •…

• Page 48
  PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER INITIAL READINGS ANNUAL 3000 km 5000 km ITEM CHECKS AND MAINTENANCE JOBS 1000 km CHECK (1800 mi) (3000 mi) (600 mi) or or 3 or 6 1 month months months • Check bearing play and steering for roughness. …
• Page 49
  PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER INITIAL READINGS ANNUAL 3000 km 5000 km ITEM CHECKS AND MAINTENANCE JOBS 1000 km CHECK (1800 mi) (3000 mi) (600 mi) or or 3 or 6 1 month months months • Check hoses for cracks of damage. …

• Page 50: Removing And Installing The Panel

  Do not attempt to diagnose 1. Panel A such problems yourself. Instead, have EAU52872 a Yamaha dealer check the vehicle. If the spark plug shows signs of elec- trode erosion and excessive carbon or Panel A other deposits, it should be replaced.

• Page 51: Check Engine Oil Level

  PERIODIC MAINTENANCE AND ADJUSTMENT wire thickness gauge and, if necessary, past finger tight. However, the spark EAU52964 Engine oil and oil filter adjusted to specification. plug should be tightened to the speci- element fied torque as soon as possible. The engine oil level should be checked before each ride.

• Page 52
  PERIODIC MAINTENANCE AND ADJUSTMENT And do not touch the radiator pipe after high-speed operation, otherwise the cooling system is hot and cause burns. Always let the engine oil cool down suffi- ciently before removing the oil tank cap. NOTICE: Do not [EWA16140] operate the vehicle until you know that the engine oil level is…

• Page 53: Change Engine Oil

  PERIODIC MAINTENANCE AND ADJUSTMENT 6. Install the engine oil tank cap, and and the engine oil filler cap. then the check bolt and its gasket. To change the engine oil (with or without oil filter element replace- ment) 1. Place the vehicle on a level sur- face.

• Page 54
  PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torques: Engine oil drain bolt (oil tank): Skip steps 8–10 if the oil filter element 20 Nm (2.0 m·kgf, 14 ft·lbf) is not being replaced. Engine oil drain bolt (crank case): 20 Nm (2.0 m·kgf, 14 ft·lbf) 8.

• Page 55: Coolant

  If this occurs,  Make sure that no foreign mate- have a Yamaha dealer repair the EAUM1295 rial enters the crankcase. vehicle. To check the coolant level …

• Page 56: Change Coolant

  The coolant should be at the bottom of sion. If water has been added to the radiator filler neck. The level will the coolant, have a Yamaha change with variation of engine temper- 1. Coolant drain bolt dealer check the antifreeze con- ature.

• Page 57: Cleaning The Air Filter Element And Check Hose

  9. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system. 1. Holding clip 2. Air filter element 3.

• Page 58
  Recommended oil: erly seated in the air filter case. Yamaha foam air filter oil or other The engine should never be op- quality foam air filter oil erated without the air filter ele- 1.
• Page 59
  PERIODIC MAINTENANCE AND ADJUSTMENT 1. Hole 1. Holding clip 1. Air filter check hose 2. Projection 2. Projection 2. If dirt or water is visible, remove 3. Air filter element 8. Close the air filter case cover, and the hose, clean it, and then install 7.

• Page 60: Adjusting The Engine Idling Speed

  Yamaha dealer make the adjustment. turn the screw in direction (a). To and, if necessary, have a Yamaha decrease the engine idling speed, dealer adjust it. turn the screw in direction (b).

• Page 61: Valve Clearance

  Tire air pressure (measured on cold from occurring, the valve clearance small area of road contact. Therefore, it tires): must be adjusted by a Yamaha dealer is essential to maintain the tires in good 0–90 kg (0–198 lb): Front: at the intervals specified in the periodic condition at all times and replace them 150 kPa (1.50 kgf/cm…

• Page 62
  Yamaha dealer re-  The replacement of all wheel- place the tire immediately.

• Page 63: Spoke Wheels

  If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel. A de- formed or cracked wheel must be replaced.

• Page 64: Checking The Brake Lever Free Play

  1. No brake lever free play (b). There should be no free play at the brake lever end. If there is free play, have a Yamaha dealer inspect the brake system. EWA14211 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system.

• Page 65: Checking The Shift Pedal

  Brake light switches dent. The operation of the shift pedal should be checked before each ride. If opera- tion is not smooth, have a Yamaha dealer check the vehicle. 1. Rear brake light switch 2. Rear brake light switch adjusting nut…

• Page 66: Checking The Front And Rear Brake Pads

  PERIODIC MAINTENANCE AND ADJUSTMENT EAU22392 peared, have a Yamaha dealer replace EAU22581 Checking the front and rear Checking the brake fluid level the brake pads as a set. brake pads Before riding, check that the brake fluid is above the minimum level mark.

• Page 67: Changing The Brake Fluid

  Rear brake may deteriorate, causing leak- EAU52952 Changing the brake fluid age. Have a Yamaha dealer change the  Refill with the same type of brake fluid at the intervals specified in brake fluid. Adding a brake fluid the periodic maintenance and lubrica- other than DOT 4 may result in a tion chart.

• Page 68: Drive Chain Slack

  EAU34317 To adjust the drive chain slack 3. Pull the drive chain up above the Consult a Yamaha dealer before ad- drive chain guard installation bolt justing the drive chain slack. with a force of 50 N (5.0 kgf, 11 1.

• Page 69: Cleaning And Lubricating The Drive Chain

  PERIODIC MAINTENANCE AND ADJUSTMENT nuts to their specified torques. EAU23025 may contain substances that Cleaning and lubricating the could damage the O-rings. [ECA11111] Tightening torques: drive chain Axle nut: The drive chain must be cleaned and 125 Nm (12.5 m·kgf, 90 ft·lbf) lubricated at the intervals specified in Locknut: the periodic maintenance and lubrica-…

• Page 70: Checking And Lubricating The Cables

  Yamaha dealer at the intervals speci- bricated if necessary. ed if necessary. If a cable is damaged fied in the periodic maintenance chart.

• Page 71: Checking And Lubricating The Brake Pedal

  EWA10731 Lithium-soap-based grease WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Otherwise, the sidestand could contact the ground and distract the operator, re- sulting in a possible loss of control.

• Page 72: Lubricating The Swingarm Pivots

  The swingarm pivots must be lubricat- intervals specified in the periodic main- ed by a Yamaha dealer at the intervals tenance and lubrication chart. specified in the periodic maintenance and lubrication chart.

• Page 73: Checking The Steering

  If any free This model is equipped with a VRLA the wheel bearings. play can be felt, have a Yamaha (Valve Regulated Lead Acid) battery. dealer check or repair the steering. There is no need to check the electro- lyte or to add distilled water.

• Page 74: To Store Battery

  To charge the battery necessary. Have a Yamaha dealer charge the bat- 3. Fully charge the battery before in- tery as soon as possible if it seems to stallation. NOTICE: When install- have discharged.

• Page 75: Replacing The Fuse

  ECA10650 NOTICE 4. If the fuse immediately blows Take care not to damage the follow- again, have a Yamaha dealer ing parts: check the electrical system.  Headlight bulb Do not touch the glass part of the headlight bulb to keep it free 1.

• Page 76
  7. Have a Yamaha dealer adjust the 1. Do not touch the glass part of the bulb. headlight beam if necessary. 1. Remove the headlight cowling to- 1.

• Page 77: Tail/Brake Light

  1. Remove the turn signal light lens If the tail/brake light does not come on, by removing the screw. have a Yamaha dealer check it. 1. Turn signal light bulb 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops.

• Page 78: Replacing The License Plate Light Bulb

  PERIODIC MAINTENANCE AND ADJUSTMENT EAU24313 EAU45224 Replacing the license plate Replacing an auxiliary light light bulb bulb 1. Remove the license plate light unit If the auxiliary light bulb burns out, re- by removing the screws. place it as follows. 1.

• Page 79: Supporting The Motorcycle

  PERIODIC MAINTENANCE AND ADJUSTMENT EAU24350 frame in front of the rear wheel or under Supporting the motorcycle each side of the swingarm. Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up- right.

• Page 80: Front Wheel

  PERIODIC MAINTENANCE AND ADJUSTMENT EAU24360 installing the spacers, be sure Front wheel to install them on the correct side. [ECA17700] EAU49332 2. Lift the wheel up between the fork To remove the front wheel legs. EWA10821 WARNING Make sure that there is enough space To avoid injury, securely support the between the brake pads before install- vehicle so there is no danger of it…

• Page 81: Rear Wheel

  PERIODIC MAINTENANCE AND ADJUSTMENT EAU25080 Tightening torque: Rear wheel Front wheel axle pinch bolt: 21 Nm (2.1 m·kgf, 15 ft·lbf) EAU45183 To remove the rear wheel 8. Push down hard on the handlebar EWA10821 several times to check for proper WARNING fork operation.

• Page 82
  PERIODIC MAINTENANCE AND ADJUSTMENT into the slot in the swingarm. Tightening torques:  Make sure that there is enough Axle nut: The drive chain does not need to be space between the brake pads be- 125 Nm (12.5 m·kgf, 90 ft·lbf) disassembled in order to remove and Locknut: fore installing the wheel.

• Page 83: Troubleshooting

  The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.

• Page 84: Troubleshooting Charts

  Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the compression. 4. Compression The engine does not start. Have a There is compression.

• Page 85
  Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

• Page 86: Motorcycle Care And Storage

  Be ble. Rust and corrosion can develop Cleaning sure to consult a Yamaha dealer for even if high-quality components are ECA10772 advice on what products to use be- NOTICE used.

• Page 87
  MOTORCYCLE CARE AND STORAGE off any detergent residue using Test the product on a small hid- remain well into spring. plenty of water, as it is harmful den part of the windshield to 1. Clean the motorcycle with cold wa- to plastic parts.

• Page 88: Storage

  EWA11131  Consult a Yamaha dealer for ad- WARNING ECA10810 NOTICE vice on what products to use. Contaminants on the brakes or tires …

• Page 89
  MOTORCYCLE CARE AND STORAGE stabilizer (if available) to prevent pivoting points of all levers and the fuel tank from rusting and the pedals as well as of the sidestand/ fuel from deteriorating. centerstand. 3. Perform the following steps to pro- 5.

• Page 90: Specifications

  SPECIFICATIONS Dimensions: EAU50975 Displacement: With oil filter element replacement: 449 cm 1.00 L (1.06 US qt, 0.88 Imp.qt) Overall length: Bore  stroke: Cooling system: 2315 mm (91.1 in) 95.0  63.4 mm (3.74  2.50 in) Overall width: Radiator capacity (including all routes): Compression ratio: 825 mm (32.5 in) 1.04 L (1.10 US qt, 0.92 Imp.qt)

• Page 91
  SPECIFICATIONS Transmission type: Manufacturer/model: Operation: Constant mesh 5-speed BRIDGESTONE/GRITTY-ED04 E Right foot operation Operation: Maximum load: Specified brake fluid: Left foot operation 90 kg (198 lb) DOT 4 Gear ratio: * (Total weight of rider, cargo and accesso- Front suspension: 1st: ries) Type:…
• Page 92
  SPECIFICATIONS Tail/brake light: Front turn signal light: 12 V, 10.0 W  2 Rear turn signal light: 12 V, 10.0 W  2 Auxiliary light: 12 V, 5.0 W  1 License plate light: 12 V, 5.0 W  1 Meter lighting: EL (Electroluminescent) Neutral indicator light:…

• Page 93: Consumer Information

  Record the vehicle identification num- ber and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER: 1. Vehicle identification number 1.

• Page 94
  INDEX Air filter element and check hose, Front and rear brake pads, checking..6-23 Panel, removing and installing ….6-7 cleaning ……….6-14 Front fork, adjusting……… 3-14 Parking …………5-5 Auxiliary light bulb, replacing ….6-35 Front fork, bleeding……..3-15 Part locations ……….2-1 Front fork, checking ………
• Page 95
  INDEX Turn signal switch……..3-7 Valve clearance ……..6-18 Vehicle identification number…..9-1 Wheel bearings, checking …….6-30 Wheel (front)……….6-37 Wheel (rear)……….6-38 Wheels………….6-20…
• Page 98
  PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2012.08-0.4×1 !

1. Manuals
2. Brands
3. Yamaha Manuals
4. Motorcycle
5. WR450FB 2012
6. Owner’s service manual

• Page 7: Table Of Contents

  TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST- MENTS TUNING CHASIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLE SHOOTING…

• Page 206: Engine

  ENGINE ENGINE REMOVAL ………………6-1 REMOVING THE ENGINE …………….. 6-4 CLEANING THE SPARK ARRESTER …………6-4 INSTALLING THE ENGINE …………..: ..6-5 INSTALLING THE EXHAUST PIPE AND MUFFLER ……… 6-5 INSTALLING THE SHIFT PEDAL ………….. 6-6 CAMSHAFT …………………. 6-7 REMOVING THE CAMSHAFT …………..

• Page 244: Clutch

  CLUTCH the clutch ,�rg 6-36…

• Page 245
  CLU TCH Remo ving the clutch 10 Nm (1.0 m, kgf, 7.2 ft, lbf) 33 Nm (3.3 m , kgf, 24 ft , lbf) 12 Nm (1.2 m, kgf, 8.7 ft, lbf) 10 Nm (1.0 m. kgf, 7.2 ft· lbf) 10 Nm (1.0 m, kgf, 7.2 ft.
• Page 246
  CLUTCH Removing the clutch 10 Nm (1.0 m. kgf, 7.2 ft· lbf) 33 Nm (3.3 m • kgf, 24 ft — lbf) 12 Nm (1.2 m • kgf, 8. 7 ft • lbf) 10 Nm (1.0 m • kgf, 7.2 ft• lbf) Order Job/Parts to remove Remarks…

• Page 247: Removing The Clutch

  CLUTCH EAS25070 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Remove: • Clutch boss nut «1» • Conical washer «2» • Clutch boss «3» TIP ______________ While holding the clutch boss with the universal clutch holder «4», loosen the clutch boss nut. Universal clutch holder EAS25110 CHECKING THE CLUTCH PLATES…

• Page 249: Checking The Primary Drive Gear

  CLUTCH CHECKING THE PRIMARY DRIVE GEAR 1. Check: • Primary drive gear Damage/wear -+ Replace the primary drive and primary driven gears as a set. Excessive noise during operation -+ Re­ place the primary drive and primary driven gears as a set. 2.

• Page 250
  CLUTCH 6. Install: 4. Install: • Push rod 2 «1» • Friction plate «1» • Ball «2» • Clutch plate 1 [t=2.0 mm (0.079 in)] «2» • Push rod 1 «3» • Clutch plate 2 [t=1.6 mm (0.063 in)] «3» TIP _____________ _ TIP _____________ _ •…

• Page 254: Kickstater

  KICKSTATER 5. Hook: • Torsion spring «1» TIP ____________ _ Turn the torsion spring clockwise and hook into the proper hole «a» in the crankcase. 3. Install: • Spring guide «1» TIP _____________ _ Slide the spring guide into the kick shaft, make sure the groove «a»…

• Page 256: Shift Shaft

  SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m. kgf, 7.2 ft. lbf) 30 Nm (3.0 m · kgf, 22 ft · lbf) Order Job/Parts to remove Remarks Q’ty Washer Stopper lever spring Segment For installation, reverse the removal proce­ dure.

• Page 257: Removing The Segment

  SHIFT SHAFT EAS10X3180 REMOVING THE SEGMENT 1. Remove: • Bolt (segment) «1» • Segment «2» TIP _____________ _ Turn the segment counterclockwise until it stops and loosen the bolt. ECA1DX1021 If the segment gets an impact, it may be EAS1DX3181 damaged.

• Page 258: Installing The Shift Guide And Shift Lever Assembly

  SHIFT SHAFT —— 4. Install: • Shift guide bolt «1» EAS1DX3183 INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY Shift guide bolt 1. Install: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Spring «1» • Pawl pin «2» • Pawl «3» To shift lever «4».

• Page 259: Oil Pump And Balancer Gear

  OIL PUMP AND BALANCER GEAR EAS1DX3184 OIL PUMP AND BALANCER GEAR Removing the oil pump and balancer 45 Nm (4.5 m • kgf, 33 ft · lbf) 10 Nm (1.0 m. kgf, 7.2 ft. lbf) 110 Nm (11.0 m • kgf, 80 ft• lbf) 50 Nm (5.0 m •…

• Page 260
  OIL PUMP AND BALANCER GEAR Removing the oil pump and balancer 45 Nm (4.5 m • kgf, 33 ft , lbf) 10 Nm (1.0 m, kgf, 7.2 ft• lbf) lbf) 110 Nm (11.0 m • kgf, 80 ft 50 Nm (5.0 m • kgf, 36 ft , lbf) Order Job/Parts to remove Remarks…
• Page 261
  OIL PUMP AND BALANCER GEAR Disassembling the oil pump 2 Nm (0.2 m • kgf, 1.4 ft· lbf) Order Job/Parts to remove Remarks Q’ty Oil pump cover Outer rotor 1 Inner rotor 1 Dowel pin Washer Oil pump drive shaft Rotor housing For assembly, reverse the disassembly pro- cedure.

• Page 263: Assembling The Oil Pump

  OIL PUMP AND BALANCER GEAR EAS1DX3187 ASSEM BLING THE OIL PUMP 1. Install: • Oil pump drive shaft «1» • Washer»2″ •• Dowel pin «3» • Inner rotor 1 «4» TIP _____ _____ _ _ _ _ • Apply the engine oil on the oil pump drive shaft and inner rotor 1.

• Page 264
  OIL PUMP AND BALANCER GEAR • Primary drive gear «3» • Conical washer «4»1m1J 5 » • Primary drive gear nut Primary drive gear nut 110 Nm (11.0 m·kgf, 80 fNbf) • Straight key «6» • Balancer «7» • Lock washer «8»1m1J •…

• Page 265: Generator And Starter Clutch

  GENERATOR AND STARTER CLUTCH EAS1DX3189 GENERATOR STARTER CLUTCH Removing the generator /jl:. — lbf)I 12 Nm (1.2 m, leg!, 8.7 ft, · · 7 Nm (0.7 m • kgf, 5.1 ft •lbf) 10 Nm (1.0 m. kgf, 7.2 ft lbf) 10 Nm (1.0 m.

• Page 266
  GENERATOR AND STARTER CLUTCH Removing the generator � 12 Nm (1.2 m • kgf, 8.7 ft lbf) 7 Nm (0.7 m, kgf, 5.1 ft ,lbf) 10 Nm (1.0 m. kgf, 7.2 ft lbf) 10 Nm (1.0 m. kgf, 7.2ft,lbf) 10 Nm (1.0 m. kgf, 7.2ft,lbf) 1: s l Y’·—(@ 6 5 Nm (6.

• Page 267: Removing The Generator

  GENERATOR AND STARTER CLUTCH EA$1DX3190 2. Check: REMOVING THE GENERATOR • Starter clutch idle gear 1. Remov e : • Starter clutch gear • Generator rotor nut «1» Burrs/chips/roughness/wear� Replace the • Washer defective part (s). 3. Check: • Starter clutch gear Damage/pitting/wear �…

• Page 268: Installing The Starter Clutch

  • Tighten the stator bolt using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. Starter clutch bolt 16 Nm (1.6 m·kgf, 12 ft-lbf) YAMAHA Bond No. 1215 (Three­ LOCTITE® Bond No. 1215®) 90890-85505 EAS1DX3193 INSTALLING THE GENERATOR 1.

• Page 269
  GENERATOR AND STARTER CLUTCH 2. Install: • Washer • Generator rotor nut «1» Generator rotor nut 65 Nm (6.5 m·kgf, 47 fMbf) TIP _____________ _._ Tighten the generator rotor nut to 65 Nm (6.5 m·kgf, 47 ft-lbf), loosen and retighten the gener­ ator rotor nut to 65 Nm (6.5 m·kgf, 47 ft·lbf).
• Page 270
  CRANKCASE CRANKCASE EAS25540 Separating the crankcase 12 Nm (1.2 m. kgf, 8.7 ft· lbf) 10 Nm (1.0 m • kgf, 7.2 ft· lbf) 10 Nm (1.0 m, kgf, 7.2 ft• lbf) Job/Parts to remove Remarks Order Q’ty Engine Refer to «ENGINE REMOVAL» on page 6-1. Refer to «CYLINDER AND PISTON»…

• Page 271: Crankcase

  CRANKCASE Separating the crankcase 12 Nm (1.2 m • kgf, 8.7 ft• lbf) 10 Nm (1.0 m • kgf, 7.2 ft• lbf) 10 Nm (1.0 m. kgf, 7.2 ft• lbf) Order Job/Parts to remove Remarks Q’ty For installation, reverse the removal proce­ dure.

• Page 272
  CRANKCASE 6-64…

• Page 273: Disassembling The Crankcase

  CRANKCASE EAS25570 DISASSEM BLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT a. Remove the crankcase bolts, hose guide and clutch cable holder. ··�·············��·��··�········ c. Remove the dowel pins and 0-ring. 2. Remove: • Balancer shaft «1» TIP ______________ _ Remove the balancer shaft with its flat side «a»…

• Page 274: Assembling The Crankcase

  (2) stages, with 1/4 turn each. the screw head. 2. Thoroughly clean all the gasket mating sur­ faces and crankcase mating surfaces. 3. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No.1215 (Three � ,?’- Bond No.1215®) 90890-85505 3. M6 x80mm 4. M6x60mm 5.

• Page 275: Crankshaft Assembly And Balancer Shaft

  CRANKSHAFT ASSEMBL V AND BALANCER SHAFT EAS25970 CRANKS HAFT ASSEMB LY AND BALANC ER SHAFT Removing the crankshaft assembly and balancer shaft Order Job/Parts to remove Remarks Q’ty Separate. Crankcase Refer to»CRANKCASE» on page 6-62. Balancer shaft Crankshaft assembly For installation, reverse the removal proce­ dure.

• Page 276: Crankshaft Assembly And Balancer Shaft

  CRANKSHAFT ASSEMBLY AND BALANCER SHAFT EAS26060 EAS1DX3195 REMOVING THE BALANCER SHAFT CHECKING THE CRANKSHAFT ASSEMBLY 1. Measure: 1. Remove: • Crankshaft runout • Balancer shaft «1» Out of specification -, Replace the crank­ TIP _____________ _ shaft, bearing or both. Remove the balancer shaft with its flat side «a»…

• Page 277: Installing The Crankshaft Assembly

  CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ECA13970 _j _______ _ To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. TIP _____________ _ Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other.

• Page 278
  TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks .._ Q ‘ t y Order Job/Parts to remove Remarks Separate. Crankcase Refer to»CRANKCASE» on page 6-62. Main axle assembly Drive axle assembly Shift drum Shift fork-R Shift fork-C Shift fork-L Collar For installation, reverse the removal proce-…
• Page 279
  TRANSMISSION EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • Shift fork cam follower «1» • Shift fork pawl «2» Bends/damage/scoring/wear� Replace the shift fork. EAS1DX3196 CHECKING THE TRANSMISSION 1. Measure: •…
• Page 280
  TRANSMISSION • Transmission gear: dogs TIP _____________ _ Cracks/damage/rounded edges -+ Replace • Apply the molybdenum disulfide oil on the in­ the defective gear (s). ner and end surface of the idler gear and on 4. Check: the inner surface of the sliding gear, then in­ •…
• Page 281
  TRANSMISSION 4. Install: • Collar «1» TIP _____________ _ • Apply the lithium soap base grease on the oil seal lip. • When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip. 6. Install: •…

инструкцияYamaha WR450F (2006)

5TJ-28199-44

WR450F(W)

OWNER’S SERVICE MANUAL

MANUEL D’ATELIER DU

PROPRIETAIRE

FAHRER- UND

WARTUNGS-HANDBUCH

MANUAL DE SERVICIO

DEL PROPIETARIO

PRINTED IN JAPAN

2006.09-2.5×1 CR

(E,F,G,S)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

Посмотреть инструкция для Yamaha WR450F (2006) бесплатно. Руководство относится к категории мотоциклы, 10 человек(а) дали ему среднюю оценку 8.3. Руководство доступно на следующих языках: английский. У вас есть вопрос о Yamaha WR450F (2006) или вам нужна помощь? Задайте свой вопрос здесь

• ENGLISH
• FRENCH
• GERMAN
• SPANISH

Мотоцикл Yamaha WR450F (2006) — это эндуро-модель, предназначенная для езды по бездорожью. Он оснащен 5-скоростной коробкой передач, ручным запуском и 4-тактным двигателем объемом 449 куб.см. Модель оснащена электронным карбюратором и системой впрыска топлива. Вес мотоцикла составляет около 113 кг. Его передняя вилка Showa BPF и задний амортизатор KYB исключают детонацию и обеспечивают мягкую езду по бездорожью. Один из кузовных элементов — рама из алюминия, благодаря чему мотоцикл устойчив и легок. Высота сиденья составляет 98,5 см.

Yamaha WR450F имеет настройки подвески, которые можно изменять, а также выносливые гусиничные усиления, которые защищают мотоцикл от повреждений. Это мотоцикл для спортивных любителей и профессионалов, разработанный для езды по труднодоступным местам. Yamaha WR450F (2006) имеет мощный мотор, который обеспечивает гладкую, плавную езду в условиях внедорожья. Он предлагает высокую функциональность и прочность за счет использования высококачественных материалов.

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WR450FR

OWNER’S SERVICE MANUAL

©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, October 2002

All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited.

Printed in Japan

P/N. LIT-11626-16-43

GENERAL INFORMATION

GEN 1 INFO

SPECIFICATIONS

SPEC 2

ENGINE

ENG 4

CHASSIS

CHAS 5

– +

ELECTRICAL

ELEC 6

TUNING

TUN 7

IJKL B C D E F

MACHINE IDENTIFICATION

There are two significant reasons for knowing the serial number of your machine:

1.When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.

2.If your machine is stolen, the authorities will need the number to search for and identify your machine.

EC121001

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is

stamped on the right of the steering head pipe.

1

EC123001

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into 1 the elevated part of the right-side of the

engine.

EC124000

MODEL LABEL

The model label 1 is affixed to the frame under the rider’s seat. This information will be needed to order spare parts.

ALL REPLACEMENT PARTS

1.We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

EC133000

GASKETS, OIL SEALS AND O-RINGS

1.All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.

2.Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

EC134000

LOCK WASHERS/PLATES AND COTTER PINS

1.All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

EC135001

BEARINGS AND OIL SEALS

1.Install the bearing(s) 1 and oil seal(s) 2 with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

CAUTION:

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

1 — 4

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

NOTE:

●For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.

●For others, use part number starting with “90890-”.

1 — 7

CONTROL FUNCTIONS

MAIN SWITCH

Functions of the respective switch positions are as follows:

ON:

The engine can be started only at this position. OFF:

All electrical circuits are switched off.

Main switch indicator light

The main switch 1 is equipped with an indicator light 2 to avoid forgetting to turn it off. This light functions as follows.

●It lights up with the main switch “ON”.

●It goes out when the engine increases its speed after being started.

●It lights up again when the engine is stopped.

NOTE:

If the indicator light will not light up with the main switch “ON”, it shows a lack of the battery voltage. Recharge the battery. If the engine is kick started, turn off the light switch.

EC151000

“ENGINE STOP” BUTTON

The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop.

START SWITCH

The start switch 1 is located on the right handlebar. Push this switch to crank the engine with the starter.

1 — 10

GEN

CONTROL FUNCTIONS INFO

EC152000

CLUTCH LEVER

The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

EC153000

SHIFT PEDAL

The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine.

EC154000

KICKSTARTER

Rotate the kickstarter 1 away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

EC155001

THROTTLE GRIP

The throttle grip 1 is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

EC156000

FRONT BRAKE LEVER

The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to activate the front brake.

1 — 11

GEN

CONTROL FUNCTIONS INFO

LIGHTS SWITCH

The lights switch 1 is located on the handlebar.

EC15F000

VALVE JOINT

This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose.

CAUTION:

In this installation, make sure the arrow faces the fuel tank and also downward.

SPARK PLUG WRENCH

This spark plug wrench 1 is used to remove and install the spark plug.

NIPPLE WRENCH

This nipple wrench 1 is used to tighten the spoke.

Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race.

Recommended fuel: Except for ZA:

Premium unleaded gasoline only with a research octane number of 95 or higher.

For ZA:

Premium gasoline

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.

NOTE:

If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.

WARNING

●For refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire.

●Refuel after the engine, exhaust pipe, etc. have cooled off.

GEN INFO

NOTE:

Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” section

in the CHAPTER 2.

1 — 19

GEN INFO

CLEANING AND STORAGE

EC1B1000

CLEANING

Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components.

1.Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose.

2.If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.

3.Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do the job.

CAUTION:

Excessive hose pressure may cause water seepage and contamination of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers.

4.After the majority of the dirt has been hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places.

5.Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth.

6.Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust.

7.Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

1 — 20