oil YAMAHA WR 450F 2003 Owner's Manual

SPEC

2 - 19
MAINTENANCE SPECIFICATIONS
NOTE:

Tighten the rotor nut to 65 Nm (6.5 m·kg, 47 ft·lb), loosen and retighten the rotor nut to 65 Nm
(6.5 m·kg, 47 ft·lb). Starter relay:
Model/manufacturer 2768090-A/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6
Ω
at 20 ˚C (68 ˚F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221 M06/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51
Ω
at 20 ˚C (68 ˚F) ----
Fuse (amperage
×
quantity):
Main fuse 10 A
×
1 ----
Reserve fuse 10 A
×
1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M5
×
0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5
×
0.8 2 7 0.7 5.1
Rotor M12
×
1.25 1 Refer to NOTE.
Neutral switch M5
×
0.8 2 4 0.4 2.9
Starter motor M6
×
1.0 2 10 1.0 7.2
Starter relay terminal M6
×
1.0 2 4 0.4 2.9 Item Standard Limit

2 - 4
CARACTERISTIQUES D’ENTRETIEN
SPEC

CARACTERISTIQUES D’ENTRETIEN
MOTEUR
Article Standard Limite
Culasse:
Limite de déformation ---- 0,05 mm
(0,002 in)
Cylindre:
Alésage 95,00 à 95,01 mm
(3,7402 à 3,7406 in)----
Limite d’ovalisation ---- 0,05 mm
(0,002 in)
Arbre à cames:
Méthode d’entraînement Transmission par chaîne (gauche) ----
Diamètre intérieur de chapeau 22,000 à 22,021 mm
(0,8661 à 0,8670 in)----
Diamètre extérieur d’arbre à cames 21,967 à 21,980 mm
(0,8648 à 0,8654 in)----
Jeu entre arbre à cames et chapeau 0,020 à 0,054 mm
(0,0008 à 0,0021 in)0,08 mm
(0,003 in)
Dimensions de came
Admission“A”31,200 à 31,300 mm
(1,2283 à 1,2323 in)31,100 mm
(1,2244 in)
“B”22,550 à 22,650 mm
(0,8878 à 0,8917 in)22,450 mm
(0,8839 in)
Echappement“A”30,950 à 31,050 mm
(1,2185 à 1,2224 in)30,850 mm
(1,2146 in)
“B”22,494 à 22,594 mm
(0,8856 à 0,8895 in)22,394 mm
(0,8817 in)
Limite de voile d’arbre à cames ---- 0,03 mm
(0,0012 in)
A
B

2 - 14
CARACTERISTIQUES D’ENTRETIENSPEC
Roue:
Type de roue avant Roue à rayons ----
Type de roue arrière Roue à rayons ----
Taille/matériau de jante avant 21 × 1,60/aluminum ----
Taille/matériau de jante arrière 18 × 2,15/aluminum ----
Limite de voile de jante:
Radial ---- 2,0 mm
(0,08 in)
Latéral ---- 2,0 mm
(0,08 in)
Chaîne de transmission:
Type/fabricant DID520VM/DAIDO ----
Nombre de maillons 113 maillons + attache ----
Flèche de la chaîne 40 à 50 mm (1,6 à 2,0 in) ----
Longueur de chaîne (10 maillons) ----150,1 mm
(5,91 in)
Frein à disque avant:
Diamètre extérieur × épaisseur 250 × 3,0 mm (9,84 × 0,12 in) 250 × 2,5 mm
(9,84 × 0,10 in)
Epaisseur de plaquette 4,4 mm (0,17 in) 1,0 mm
(0,04 in)
Diamètre intérieur de maître-cylindre 11,0 mm (0,433 in) ----
Diamètre intérieur de cylindre d’étrier 27,0 mm (1,063 in) × 2 ----
Type de liquide de frein DOT n˚4 ----
Frein à disque arrière:
Diamètre extérieur × épaisseur 245 × 4,0 mm (9,65 × 0,16 in) 245 × 3,5 mm
(9,65 × 0,14 in)
Limite de flèche ----0,15 mm
(0,006 in)
Epaisseur de plaquette 6,4 mm (0,25 in) 1,0 mm
(0,04 in)
Diamètre intérieur de maître-cylindre 11,0 mm (0,433 in) ----
Diamètre intérieur de cylindre d’étrier 25,4 mm (1,000 in) × 1 ----
Type de liquide de frein DOT n˚4 ----
Levier de frein et pédale de frein:
Position du levier de frein 95 mm (3,74 in) ----
Hauteur de la pédale de frein
(hauteur en dessous le haut du repose-pied)5 mm (0,20 in) ----
Jeu de levier d’embrayage (au pivot du levier) 8 à 13 mm (0,31 à 0,51 in) ----
Jeu à la poignée d’accélération 3 à 5 mm (0,12 à 0,20 in) ---- Article Standard Limite

2 - 21
SPEC

LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1
Oil delivery pipe
2
Intake camshaft
3
Exhaust camshaft
4
Oil cleaner element
5
Oil pump
6
Main axle
7
Drive axle
7
6
543 2
14
5
A - A
D - D
G
G
D
D A
A

2 - 22
SPEC

LUBRICATION DIAGRAMS
1
Camshaft
2
Connecting rod
3
Oil cleaner element
4
Crankshaft
5
Main axle
6
Drive axle
7
Oil delivery pipe
1
2
3
4
5
67

2 - 23
SPEC

CABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1
Fuel tank breather hose
2
Clamp
3
Diode
4
Wire harness
5
Hot starter cable
6
Negative battery lead
7
Starter motor lead
8
TPS (throttle position sen-
sor) lead
9
Neutral switch lead
0
Oil hose
A
Hose holder
B
Radiator hose 4
C
Cylinder head breather hose
D
AC magneto lead
E
Radiator hose 1
F
Oil tank breather hose
G
Lights switch lead
H
Brake hose
I
Hose guide
J
Carburetor breather hose
K
Overflow hose
LCoolant reservoir tank breather
hose
ÅInsert the fuel tank breather
hose into the hole in the steering
shaft cap.
ıFasten the diode of the wire har-
ness and rectifier/regulator lead
(at its protecting tube) to the
frame at the white tape for the
diode with a plastic locking tie
and cut off the tie end.ÇFasten the wire harness, recti-
fier/regulator lead, coolant res-
ervoir hose and hot starter cable
to the frame with a plastic lock-
ing tie and cut off the tie end.
ÎFasten the wire harness, recti-
fier/regulator lead and coolant
reservoir hose to the frame with
a plastic locking tie and cut off
the tie end.
‰Fasten the wire harness to the
frame at its white tape with a
plastic locking tie and cut off the
tie end.

2 - 24
SPECCABLE ROUTING DIAGRAM
ÏFasten the wire harness, TPS
lead (in the wire harness),
starter motor lead and negative
battery lead to the frame with a
plastic locking tie and cut off
the tie end.
ÌMake sure that the TPS cou-
pler does not go out the chas-
sis.
ÓFasten the TPS lead to the
frame with a plastic band.
ÈFasten the neutral switch lead
and oil hose together with the
plastic locking ties and cut off
the tie ends.
ÔPass the cylinder head
breather hose through the hose
holder.Fasten the neutral switch lead
to the frame with a plastic band
ends outward.
ÒFasten the neutral switch lead
and AC magneto lead to the
frame with a plastic band.
˜Pass the cylinder head
breather hose on the outside of
the radiator hose 1 and on the
inside of the radiator pipe (radi-
ator hose 4).
ˆPass the oil tank breather hose
on the outside of the AC mag-
neto lead, neutral switch lead,
lights switch lead, wire harness
and cylinder head breather
hose.ØPass the wire harness on the
outside of the neutral switch
lead and AC magneto lead.
∏Fit the brake hose into the
guides on the protector.
ŒPass the wire harness through
the cable guide.
ÂFasten the AC magneto lead,
neutral switch lead and lights
switch lead to the cable guide
at their protecting tube with a
plastic locking tie and cut off
the tie end.
ÍPass the carburetor breather
hoses, overflow hose and cool-
ant reservoir tank breather
hose so that the hoses do not
contact the rear shock
absorber.

2 - 25
SPECCABLE ROUTING DIAGRAM
1Hot starter cable
2Clutch cable
3Throttle cable (return)
4Throttle cable (pull)
5Ignition coil
6Negative battery lead
7Starter motor lead
8Coolant reservoir tank
breather hose
9Rectifier/regulator
0Cable holder
ACoolant reservoir hose
BRectifier/regulator lead
CClamp
DCDI unit lead
ECDI unit
FCDI unit band
GCDI unit stay (frame)
HCable bracketIRectifier/regulator bracket
ÅPass the throttle cables, clutch
cable and hot starter cable through
the cable guides.
ıPass the throttle cables, clutch
cable and hot starter cable between
the radiator and frame, then over
the middle radiator mounting boss.
ÇPass the throttle cables and clutch
cable on the outside of the ignition
coil.
ÎPass the carburetor breather hose
(throttle cable cover) through the
hose holder.
‰Fasten the coolant reservoir tank
breather hose and carburetor
breather hoses together with a
plastic locking tie.ÏFasten the grommet of the clutch
cable with the cable holder.
ÌFasten the CDI unit lead to the
frame with a plastic locking tie ends
at the lower of the frame and cut off
the tie end.
ÓInsert the CDI unit band over the
CDI unit stay (frame) as far as pos-
sible.
ÈFasten the starter motor lead and
negative battery lead to the cable
bracket in its slot with a plastic lock-
ing tie and cut off the tie end.
ÔFasten the rectifier/regulator lead to
the rectifier/regulator bracket with a
plastic locking tie and cut off the tie
end.

3 - 1
INSP
ADJ

MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)
As re-
quiredRemarks
ENGINE OIL
Replace
●

●

VALVES
Check the valve clearances
Inspect
Replace
●

●

●

●
The engine must be cold.
Check the valve seats
and valve stems for wear.
VALVE SPRINGS
Inspect
Replace
●

●
Check the free length and
the tilt.
VALVE LIFTERS
Inspect
Replace
●

●
Check for scratches and
wear.
CAMSHAFTS
Inspect
Replace
●

●
Inspect the camshaft sur-
face.
Inspect the decompres-
sion system
CAMSHAFT SPROCKETS
Inspect
Replace
●

●
Check for wear on the
teeth and for damage.
PISTON
Inspect
Clean
Replace
●

●

●

●
Inspect crack
Inspect carbon deposits
and eliminate them.
PISTON RING
Inspect
Replace
●

●

●
Check ring end gap
PISTON PIN
Inspect
Replace
●

●

CYLINDER HEAD
Inspect and clean
●
Inspect carbon deposits
and eliminate them.
Change gasket
CYLINDER
Inspect and clean
Replace
●

●
Inspect score marks
Inspect wear
CLUTCH
Inspect and adjust
Replace
●

●

●
Inspect housing, friction
plate, clutch plate and
spring
TRANSMISSION
Inspect
Replace bearing
●

●

3 - 2
INSP
ADJ

MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
●
Inspect wear
ROTOR NUT
Retighten
●

●

MUFFLER
Inspect and retighten
Clean
Replace
●

●

●

●
* Whichever comes first
*SPARK ARRESTER
Clean
(Every
six
months)
●
CRANK
Inspect and clean
●

●

CARBURETOR
Inspect, adjust and clean
●

●

SPARK PLUG
Inspect and clean
Replace
●

●

●

DRIVE CHAIN
Lubricate, slack, alignment
Replace
●

●

●
Use chain lube
Chain slack: 40 ~ 50 mm
(1.57 ~ 1.97 in)
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
●

●

●

●

●
Every two years
OUTSIDE NUTS AND BOLTS
Retighten
●

●
Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricate
Replace
●

●

●
Use foam air-filter oil or
equivalent oil
OIL FILTER
Replace
●

●

OIL STRAINER (frame)
Clean
●

FRAME
Clean and inspect
●

●

FUEL TANK, COCK
Clean and inspect
●

●

BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid
●

●

●

●

●

●

●

●

●

●

●

●
Every one year ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)
As re-
quiredRemarks


3