engine YAMAHA WR 450F 2004 Owners Manual

5. GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refu-
eling. Take care to not spill any gaso-
line on the engine or exhaust system.
Never refuel in the vicinity of an open
flame, or while smoking.
6. GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline,
inhale excess gasoline vapors, or
allow any gasoline to get into your
eyes, contact a doctor immediately. If
any gasoline spills onto your skin or
clothing, immediately wash skin areas
with soap and water, and change your
clothes.
7. ONLY OPERATE THE MACHINE IN AN
AREA WITH ADEQUATE VENTILA-
TION.
Never start the engine or let it run for
any length of time in an enclosed area.
Exhaust fumes are poisonous. These
fumes contain carbon monoxide,
which by itself is odorless and color-
less. Carbon monoxide is a dangerous
gas which can cause unconscious-
ness or can be lethal.
8. PARK THE MACHINE CAREFULLY;
TURN OFF THE ENGINE.
Always turn off the engine if you are
going to leave the machine. Do not
park the machine on a slope or soft
ground as it may fall over.
9. THE ENGINE, EXHAUST PIPE, MUF-
FLER, AND OIL TANK WILL BE VERY
HOT AFTER THE ENGINE HAS BEEN
RUN.
Be careful not to touch them or to
allow any clothing item to contact
them during inspection or repair.
10. PROPERLY SECURE THE MACHINE
BEFORE TRANSPORTING IT.
When transporting the machine in
another vehicle, always be sure it is
properly secured and in an upright
position and that the fuel cock is in
the “OFF” position. Otherwise, fuel
may leak out of the carburetor or fuel
tank.

EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTENTION!
BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could
result in severe injury or death to the machine
operator, a bystander, or a person inspecting
or repairing the machine.
A CAUTION indicates special precautions that
must be taken to avoid damage to the
machine.
NOTE:
A NOTE provides key information to make pro-
cedures easier or clearer.
WARNING
CAUTION:

EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of seven chapters;
“General Information”, “Specifications”,
“Regular inspection and adjustments”,
“Engine”, “Chassis”, “Electrical” and
“Tuning”.
2. The table of contents is at the beginning
of the manual. Look over the general lay-
out of the book before finding then
required chapter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol mark
and go to a page for required item and
description.

ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbols
1
to
7
are designed as
thumb tabs to indicate the chapter’s number
and content.
1
General information
2
Specifications
3
Regular inspection and adjustments
4
Engine
5
Chassis
6
Electrical
7
Tuning
Illustrated symbols
8
to
D
are used to identify
the specifications appearing in the text.
8
With engine mounted
9
Special tool
0
Filling fluid
A
Lubricant
B
Tightening
C
Specified value, Service limit
D
Resistance (
Ω
), Voltage (V), Electric current (A)
Illustrated symbols
E
to
H
in the exploded
diagrams indicate grade of lubricant and loca-
tion of lubrication point.
E
Apply engine oil
F
Apply molybdenum disulfide oil
G
Apply lightweight lithium-soap base grease
H
Apply molybdenum disulfide grease
Illustrated symbols
I
to
J
in the exploded
diagrams indicate where to apply a locking
agent and where to install new parts.
IApply locking agent (LOCTITE®)
JUse new one 12
34
56
78
90
AB
CD
EF
GH
IJ
GEN
INFOSPEC
INSP
ADJENG
CHAS–+ELEC
TUN
T R..
EM
BM
New

EC090010
INDEX
GENERAL INFORMATION
SPECIFICATIONS
REGULAR INSPECTION AND ADJUSTMENTS
ENGINE
CHASSIS
ELECTRICAL
TUNING

EC0A0000
CONTENTS
CHAPTER 1
GENERAL INFORMATION
DESCRIPTION
...........................................1-1
MACHINE IDENTIFICATION
.....................1-2
IMPORTANT INFORMATION
....................1-3
CHECKING OF CONNECTION
.................1-6
SPECIAL TOOLS
......................................1-7
CONTROL FUNCTIONS
..........................1-10
FUEL
........................................................1-14
STARTING AND BREAK-IN
....................1-15
TORQUE-CHECK POINTS
......................1-19
CLEANING AND STORAGE
...................1-20
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS
...................2-1
MAINTENANCE SPECIFICATIONS
..........2-4
GENERAL TORQUE
SPECIFICATIONS
...................................2-20
DEFINITION OF UNITS
...........................2-20
LUBRICATION DIAGRAMS
....................2-21
CABLE ROUTING DIAGRAM
.................2-23
CHAPTER 3
REGULAR INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS
...................3-1
PRE-OPERATION INSPECTION
AND MAINTENANCE
................................3-4
ENGINE
......................................................3-5
CHASSIS
.................................................3-26
ELECTRICAL
...........................................3-48

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS
..................................4-1
EXHAUST PIPE AND SILENCER
.............4-3
RADIATOR
................................................4-5
CARBURETOR
..........................................4-8
CAMSHAFTS
...........................................4-21
CYLINDER HEAD
....................................4-29
VALVES AND VALVE SPRINGS
............4-33
CYLINDER AND PISTON
........................4-42
CLUTCH
...................................................4-48
OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT)
.....4-55
BALANCER
.............................................4-62
OIL PUMP
................................................4-65
KICK AXLE AND SHIFT SHAFT
.............4-69
AC MAGNETO
AND STARTER CLUTCH
........................4-76
ENGINE REMOVAL
.................................4-83
CRANKCASE AND CRANKSHAFT
........4-89
TRANSMISSION, SHIFT CAM
AND SHIFT FORK
...................................4-98
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL
.......5-1
FRONT BRAKE AND REAR BRAKE
.....5-11
FRONT FORK
..........................................5-27
HANDLEBAR
...........................................5-40
STEERING
...............................................5-46
SWINGARM
.............................................5-52
REAR SHOCK ABSORBER
....................5-60

CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM
...........................6-1
MAP-CONTROLLED CDI UNIT
.................6-2
IGNITION SYSTEM
....................................6-3
ELECTRIC STARTING SYSTEM
..............6-7
CHARGING SYSTEM
..............................6-17
TPS (THROTTLE POSITION SENSOR)
SYSTEM
...................................................6-19
LIGHTING SYSTEM
................................6-24
CHAPTER 7
TUNING
ENGINE
......................................................7-1
CHASSIS
.................................................7-10

GEN
INFO

1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1
Clutch lever
2
Hot starter lever
3
“ENGINE STOP” button
4
Trip meter
5
Main switch
6
Start switch
7
Front brake lever
8
Throttle grip
9
Radiator cap
0
Fuel tank cap
A
Taillight
B
Kickstarter
C
Fuel tank
D
Headlight
E
Radiator
F
Coolant drain bolt
G
Rear brake pedal
H
Valve joint
I
Fuel cock
J
Cold starter knob
K
Air cleaner
L
Drive chain
M
Shift pedal
N
Oil dipstick
O
Front fork
NOTE:


The machine you have purchased may differ
slightly from those shown in the following.

Designs and specifications are subject to
change without notice.
A
BCD
E
F G
1234
5
6
7
8
9 0
HI
J
K
L M
N O

GEN
INFO

DESCRIPTION
FAHRZEUGBESCHREIBUNG
DESCRIPCIÓN
ALLGEMEINE
ANGABEN
FAHRZEUGBESCHREI-
BUNG
1
Kupplungshebel
2
Heißstarter-Hebel
3
Motorstoppschalter “ENGINE
STOP”
4
Tageskilometerzähler
5
Hauptschalter
6
Startschalter
7
Handbremshebel
8
Gasdrehgriff
9
Kühlerverschlußdeckel
0
Kraftstoffankverschluß
A
Rücklicht
B
Kickstarter
C
Kraftstofftank
D
Scheinwerfer
E
Kühler
F
Kühlmittel-Ablaßschraube
G
Fußbremshebel
H
Auslaufschutzventil
I
Kraftstoffhahn
J
Kaltstarterknopf
K
Luftfilter
L
Antriebskette
M
Schalthebel
N
Ölmeßstab
O
Teleskopgabel
HINWEIS:


Leichte Modell-Abweichungen
möglich.

Änderungen an Design und techni-
schen Daten jederzeit vorbehalten.
RENSEIGNEMENTS
GENERAUX
DESCRIPTION
1
Levier d’embrayage
2
Levier de démarreur à chaud
3
Bouton du coupe-circuit de sécurité
“ENGINE STOP”
4
Compteur de vitesse
5
Commutateur principal
6
Commutateur de démarrage
7
Levier de frein avant
8
Poignée d’accélérateur
9
Bouchon de radiateur
0
Bouchon de réservoir à essence
A
Lampe arrière
B
Démarreur au pied
C
Réservoir de carburant
D
Phare
E
Radiateur
F
Boulon de vidange du liquide de
refroidissement
G
Pédale de frein arrière
H
Joint de robinet
I
Robinet à essence
J
Bouton de démarrage à froid
K
Filtre à air
L
Chaîne de transmission
M
Pédale de sélecteur
N
Jauge de niveau d’huile
OFourche avant
N.B.:
Votre machine diffère peut-être par-
tiellement de celles montrées sur ces
photos.
La conception et les caractéristiques
peuvent êtres changées sans préavis.
INFORMACIÓN
GENERAL
DESCRIPCIÓN
1Palanca del embrague
2Palanca de arranque en caliente
3Botón de parada del motor “ENGINE
STOP”
4Medidor de trayecto
5Interruptor principal
6Interruptor de arranque
7Palanca del freno delantero
8Empuñadura del acelerador
9Tapa del radiador
0Tapa del depósito de combustible
APiloto trasero
BArrancador de pedal
CDepósito de combustible
DFaro delantero
ERadiador
FPerno de drenaje del refrigerante
GPedal del freno trasero
HJunta de la válvula
IGrifo de combustible
JPomo de arranque en frío
KDepurador de aire
LCadena de la caja de cambios
MPedal de cambios
NVarilla del nivel de aceite
OHorquilla delantera
NOTA:
El vehículo que ha adquirido puede
diferir ligeramente de los que se mues-
tran a continuación.
Los diseños y las especificaciones
están sujetos a modificaciones sin pre-
vio aviso.
1 - 1
1

1 - 2
GEN
INFO

MACHINE IDENTIFICATION
EC120001
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 posi-
tive 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
the elevated part of the right-side of the
engine.
1

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.
1