YAMAHA WR 450F 2005 Manual Online

SPEC
2 - 6 Valve spring:
Free length IN 37.03 mm (1.46 in) 36.03 mm
(1.42 in)
EX 37.68 mm (1.48 in) 36.68 mm
(1.44 in)
Set length (valve closed) IN 27.87 mm (1.10 in) ----
EX 27.38 mm (1.08 in) ----
Compressed force
(installed) IN 111.3 ~ 127.9 N at 27.87 mm
(11.3 ~ 13.0 kg at 27.87 mm,
24.91 ~ 28.66 lb at 1.10 in)----
EX 127.4 ~ 146.4 N at 27.38 mm
(13.0 ~ 14.9 kg at 27.38 mm,
28.66 ~ 32.85 lb at 1.08 in)----
Tilt limit IN ----
2.5°/ 1.61 mm
(2.5°/0.063 in)
EX ----2.5°/1.65 mm
(2.5°/0.065 in)
Direction of winding (top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)0.1 mm
(0.004 in)
Piston size “D”94.945 ~ 94.960 mm
(3.738 ~ 3.739 in)----
Measuring point “H”8 mm (0.315 in) ----
Piston off-set 1 mm (0.0394 in) ----
Piston pin bore inside diameter 18.004 ~ 18.015 mm
(0.7088 ~ 0.7093 in)18.045 mm
(0.7104 in)
Piston pin outside diameter 17.991 ~ 18.000 mm
(0.7083 ~ 0.7087 in)17.971 mm
(0.7075 in) Item Standard Limit
*
H
D
MAINTENANCE SPECIFICATIONS

SPEC
2 - 7 Piston rings:
Top ring:
Type Barrel ----
Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ----
End gap (installed) 0.20 ~ 0.30 mm
(0.008 ~ 0.012 in)0.55 mm
(0.022 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.12 mm
(0.005 in)
2nd ring:
Type Taper ----
Dimensions (B × T) 1.00 × 3.35 mm (0.04 × 0.13 in) ----
End gap (installed) 0.35 ~ 0.50 mm
(0.014 ~ 0.020 in)0.85 mm
(0.033 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.12 mm
(0.005 in)
Oil ring:
Dimensions (B × T) 2.0 × 2.9 mm (0.08 × 0.11 in) ----
End gap (installed) 0.2 ~ 0.5 mm (0.01 ~ 0.02 in) ----
Crankshaft:
Crank width “A”61.95 ~ 62.00 mm
(2.439 ~ 2.441 in)----
Runout limit “C”0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D”0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Small end free play “F”0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm
(0.08 in)
Balancer:
Balancer drive method Gear ----
Air filter oil grade: Foam-air-filter oil or equivalent
oil ---- Item Standard Limit
T
B
B
T
B
T
MAINTENANCE SPECIFICATIONS

SPEC
2 - 8 Clutch:
Friction plate thickness 2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)2.8 mm
(0.110 in)
Quantity 8 ----
Clutch plate 1 thickness 1.9 ~ 2.1 mm (0.075 ~ 0.083 in) ----
Quantity 4 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch plate 2 thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) ----
Quantity 3 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch spring free length 50.0 mm (1.97 in) 49.0 mm
(1.93 in)
Quantity 6 ----
Clutch housing thrust clearance 0.10 ~ 0.35 mm
(0.0039 ~ 0.0138 in)----
Clutch housing radial clearance 0.010 ~ 0.044 mm
(0.0004 ~ 0.0017 in)----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm
(0.002 in)
Kickstarter:
Type Ratchet type ----
Carburetor:
I. D. mark 5TJ8 80 ----
Main jet (M.J) #165 ----
Main air jet (M.A.J)ø2.0 ----
Jet needle (J.N) NFNT ----
Cutaway (C.A) 1.5 ----
Pilot jet (P.J) #45 ----
Pilot air jet (P.A.J) #80 ----
Pilot outlet (P.O)ø0.9 ----
Bypass (B.P)ø1.0 ----
Valve seat size (V.S)ø3.8 ----
Starter jet (G.S) #65 ----
Leak jet (Acc.P) #50 ----
Float height (F.H) 8 mm (0.31 in) ----
Engine idle speed 1,700 ~ 1,900 r/min ----
Intake vacuum 34.3 ~ 40.7 kPa
(260 ~ 300 mmHg,
10.24 ~ 11.81 inHg)----
Hot starter lever free play 3 ~ 6 mm (0.12 ~ 0.24 in) ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 9 Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance “A”0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Tip clearance “B”0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Side clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.007 in)
Bypass valve setting pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm
2,
5.69 ~ 11.38 psi)----
Cooling:
Radiator core size
Width 117.8 mm (4.6 in) ----
Height 260 mm (10.2 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.71 L (0.62 Imp qt, 0.75 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 10 Item Standard
Lubrication chart:
Pressure feed
Splashed scavenge
Oil strainer
Oil pan Oil pump rotor 2
Oil pump rotor 1
Oil tank
Oil filter
Check ball
Cylinder head
Crank pinPiston pinPiston
Drive axleMain axleTransmission gears
Camshaft
Valve lifter
MAINTENANCE SPECIFICATIONS

SPEC
2 - 11 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
M8 × 1.25 1 15 1.5 11
(bolt) M10 × 1.25 4 Refer to NOTE.*
1
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Timing chain guide (rear) M6 × 1.0 2 10 1.0 7.2
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 16 1.6 11
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
Spark arrester M5 × 0.8 4 7 0.7 5.1
Silencer cap M5 × 0.8 6 5 0.5 3.6
Carburetor joint clamp (cylinder head side) M5 × 0.8 1 3 0.3 2.2
Carburetor joint clamp (carburetor side) M4 × 0.7 1 3 0.3 2.2
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Radiator panel (upper) M6 × 1.0 2 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Radiator pipe 1, 2 M10 × 1.0 2 10 1.0 7.2
Impeller M8 × 1.25 1 14 1.4 10
Water pump housing cover M6 × 1.0 3 10 1.0 7.2
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 9 0.9 6.5
Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2
Oil filter cover M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 M10 × 1.25 1 20 2.0 14
M8 × 1.25 2 18 1.8 13
Oil delivery pipe 2 M6 × 1.0 1 10 1.0 7.2
Oil hose M6 × 1.0 2 8 0.8 5.8
MAINTENANCE SPECIFICATIONS

SPEC
2 - 12
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.
NOTE:
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m  kg, 22 ft  lb) in the proper tightening sequence,
remove and retighten the cylinder head bolts to 20 Nm (2.0 m  kg, 14 ft  lb) in the proper tightening
sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the
proper tightening sequence.Oil check bolt M6 × 1.0 1 10 1.0 7.2
Oil hose clamp—220.21.4
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase cover (right) M6 × 1.0 10 10 1.0 7.2
Crankcase cover (left) M6 × 1.0 9 10 1.0 7.2
Idle gear cover (starter motor) M6 × 1.0 2 10 1.0 7.2
Crankcase M6 × 1.0 12 12 1.2 8.7
Clutch cable holder M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (crankcase rear) M10 × 1.25 1 20 2.0 14
(crankcase left) M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (frame) M8 × 1.25 1 23 2.3 17
Oil strainer (frame) M14 × 1.5 1 70 7.0 50
Crankcase bearing stopper M6 × 1.0 15 10 1.0 7.2
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter M8 × 1.25 1 33 3.3 24
Screw (kickstarter) M6 × 1.0 1 7 0.7 5.1
Starter clutch M6 × 1.0 6 16 1.6 11
Primary drive gear M20 × 1.0 1 110 11.0 80
Clutch boss M20 × 1.0 1 75 7.5 54
Push lever M6 × 1.0 1 10 1.0 7.2
Clutch spring M6 × 1.0 6 8 0.8 5.8
Balancer driven gear M14 × 1.0 1 50 5.0 36
Balancer weight plate M6 × 1.0 3 10 1.0 7.2
Drive sprocket M20 × 1.0 1 75 7.5 54
Drive sprocket cover M6 × 1.0 2 8 0.8 5.8
Shift pedal M6 × 1.0 1 12 1.2 8.7
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
MAINTENANCE SPECIFICATIONS

SPEC
2 - 13
EC212201
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN EUROPE AUS, NZ, ZA
Front fork travel 300 mm (11.8 in)← ←
Fork spring free length 460 mm (18.1 in)← ←
Spring rate, STD K = 4.5 N/mm
(0.459 kg/mm,
25.7 lb/in)K = 4.2 N/mm
(0.428 kg/mm,
24.0 lb/in)K = 4.4 N/mm
(0.449 kg/mm,
25.1 lb/in)
Optional spring/spacer Yes← ←
Oil capacity 718 cm
3
(25.3 Imp oz,
24.3 US oz) 715 cm3
(25.2 Imp oz,
24.2 US oz) ←
Oil level 128 mm (5.04 in) 130 mm (5.12 in)←

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 150 mm
(3.15 ~ 5.91 in)← ←
Oil grade Suspension oil
“S1”← ←
Inner tube outer diameter 48 mm (1.89 in)← ←
Front fork top end Zero mm (Zero in)← ←
Rear suspension: USA, CDN EUROPE AUS, NZ, ZA
Shock absorber travel 129 mm (5.08 in)← ←
Spring free length260 mm (10.24 in)← ←
Fitting length 248 mm (9.76 in) 253 mm (9.96 in) 247 mm (9.72 in)
237.5 ~ 258.5 mm
(9.35 ~ 10.18 in)← ←
Spring rate, STD K = 52.0 N/mm
(5.30 kg/mm,
296.8 lb/in)K = 48.0 N/mm
(4.90 kg/mm,
274.4 lb/in)K = 54.0 N/mm
(5.50 kg/mm,
308.0 lb/in)
Optional spring Yes← ←
Enclosed gas pressure
1,000 kPa
(10 kg/cm2, 142 psi)
← ←
Swingarm:
Swingarm free play limit
End ---- 1.0 mm
(0.04 in)
MAINTENANCE SPECIFICATIONS

SPEC
2 - 14 Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 21 × 1.60/Aluminum ----
Rear rim size/material 18 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm
(0.08 in)
Lateral ---- 2.0 mm
(0.08 in)
Drive chain:
Type/manufacturer DID520VM/DAIDO ----
Number of links 113 links + joint ----
Chain slack 48 ~ 58 mm (1.9 ~ 2.3 in) ----
Chain length (15 links) ---- 239.3 mm
(9.42 in)
Front disc brake:
Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in)
250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in)
245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm
(0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)5 mm (0.20 in) ----
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 15
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m  kg, 27 ft  lb) by using the ring nut
wrench, then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m  kg, 5.1 ft  lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Handle crown and outer tube M8 × 1.25 4 23 2.3 17
Under bracket and outer tube M8 × 1.25 4 20 2.0 14
Handle crown and steering shaft M24 × 1.0 1 145 14.5 105
Handlebar holder (upper) M8 × 1.25 4 28 2.8 20
Steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M51 × 1.5 2 30 3.0 22
Front fork and base valve M27 × 1.0 2 55 5.5 40
Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21
Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and protector M6 × 1.0 6 10 1.0 7.2
Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1
Throttle cable cap M5 × 0.8 2 4 0.4 2.9
Clutch lever holder mounting M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting M6 × 1.0 1 4 0.4 2.9
Hot starter lever holder mounting M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting M5 × 0.8 1 2 0.2 1.4
Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3
Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Hose guide (front brake hose) and hose guide bracketM5 × 0.8 1 4 0.4 2.9
Hose guide (front brake hose) and under bracketM6 × 1.0 1 4 0.4 2.9
Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Front brake caliper and front fork M8 × 1.25 2 23 2.3 17
Front brake caliper and brake hose holder M6 × 1.0 1 10 1.0 7.2
Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2
Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13
Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3
Front wheel axle and nut M16 × 1.5 1 105 10.5 75
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
Brake pedal mounting M8 × 1.25 1 26 2.6 19
Rear brake master cylinder and frame M6 × 1.0 2 11 1.1 8.0
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
MAINTENANCE SPECIFICATIONS