YAMAHA WR 450F 2008 User Guide

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DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.
1. Clutch lever
2. Hot starter lever
3. Engine stop switch
4. Multi-function display
5. Main switch
6. Start switch
7. Front brake lever
8. Throttle grip
9. Radiator cap
10. Fuel tank cap
11. Taillight
12. Kickstarter crank
13. Fuel tank14. Headlight
15. Radiator
16. Coolant drain bolt
17. Rear brake pedal
18. Valve joint
19. Fuel cock
20. Cold starter knob
21. Air cleaner
22. Catch tank
23. Drive chain
24. Shift pedal
25. Oil dipstick
26. Front fork
1

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MACHINE IDENTIFICATION
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 au-
thorities will need the number to
search for and identify your ma-
chine.
VEHICLE IDENTIFICATION
NUMBER
The vehicle identification number "1"
is stamped on the right of the steering
head pipe.
ENGINE SERIAL NUMBER
The engine serial number "1" is
stamped into the elevated part of the
right-side of the engine.
MODEL LABEL
The model label "1" is affixed to the
frame under the rider's seat. This in-
formation will be needed to order
spare parts.
INCLUDED PARTS
VALVE JOINT
This valve joint "1" prevents fuel from
flowing out and is installed to the fuel
tank breather hose.
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.
JET NEEDLE PULL-UP TOOL
The jet needle pull-up tool "1" is used
to pull the jet needle out of the carbu-
retor.
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
AND DISASSEMBLY
1. Remove all dirt, mud, dust, and
foreign material before removal
and disassembly.
• When washing the machine with
high pressured water, cover the
parts follows.
Silencer exhaust port
Side cover air intake port
Water pump housing hole at the
bottom
Drain hole on the cylinder head
(right side)
All electrical components2. Use proper tools and cleaning
equipment. Refer to "SPECIAL
TOOLS" section.
3. When disassembling the ma-
chine, keep mated parts together.
They include gears, cylinders,
pistons, and other mated parts
that have been "mated" through
normal wear. Mated parts must
be reused as an assembly or re-
placed.
4. During the machine disassembly,
clean all parts and place them in
trays in the order of disassembly.
This will speed up assembly time
and help assure that all parts are
correctly reinstalled.
5. Keep away from fire.

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CHECKING OF CONNECTION
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha
genuine parts for all replace-
ments. Use oil and/or grease rec-
ommended by Yamaha for
assembly and adjustment.
GASKETS, OIL SEALS AND O-
RINGS
1. All gaskets, oil seals, and O-rings
should be replaced when an en-
gine is overhauled. All gasket sur-
faces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and
bearings during reassembly. Ap-
ply grease to the oil seal lips.
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.
BEARINGS AND OIL SEALS
1. Install the bearing(s) "1" and oil
seal(s) "2" with their manufactur-
er's marks or numbers facing out-
ward. (In other words, the
stamped letters must be on the
side exposed to view.) When in-
stalling oil seal(s), apply a light
coating of lightweight lithium base
grease to the seal lip(s). Oil the
bearings liberally when installing.
Do not use compressed air to spin
the bearings dry. This causes dam-
age to the bearing surfaces.
CIRCLIPS
1. All circlips should be inspected
carefully before reassembly. Al-
ways replace piston pin clips after
one use. Replace distorted cir-
clips. When installing a circlip "1",
make sure that the sharp-edged
corner "2" is positioned opposite
to the thrust "3" it receives. See
the sectional view.
CHECKING OF
CONNECTION
Dealing with stains, rust, moisture,
etc. on the connector.
1. Disconnect:
• Connector
2. Dry each terminal with an air
blower.
3. Connect and disconnect the con-
nector two or three times.
4. Pull the lead to check that it will
not come off.
5. If the terminal comes off, bend up
the pin "1" and reinsert the termi-
nal into the connector.
6. Connect:
• Connector
The two connectors "click" together.
7. Check for continuity with a tester.
• If there in no continuity, clean the
terminals.
• Be sure to perform the steps 1 to 7
listed above when checking the
wire harness.
• For a field remedy, use a contact re-
vitalizer available on the market.
• Use the tester on the connector as
shown.

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SPECIAL TOOLS
SPECIAL TOOLS
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.
• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
• For others, use part number starting with "90890-".
Tool name/Part number How to use Illustration
Dial gauge and stand
YU-3097, 90890-01252
Stand
YU-1256These tools are used to check each
part for runout or bent.
Crankshaft installing tool
Crankshaft installing pot
YU-90050, 90890-01274
Crankshaft installing bolt
YU-90050, 90890-01275
Spacer (crankshaft installer)
YM-91044, 90890-04081
Adapter (M12)
YU-90063, 90890-01278These tools are used to install the
crankshaft.
Piston pin puller set
YU-1304, 90890-01304 This tool is used to remove the pis-
ton pin.
Radiator cap tester
YU-24460-01, 90890-01325
Radiator cap tester adapter
YU-33984, 90890-01352These tools are used for checking
the cooling system.
Steering nut wrench
YU-33975, 90890-01403 This tool is used when tighten the
steering ring nut to specification.

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SPECIAL TOOLS
Damper rod holder
YM-01494, 90890-01494Use this tool to remove and install
the damper rod.
Fork seal driver
YM-A0948, 90890-01502 This tool is used when install the fork
oil seal.
Sheave holder
YS-1880-A, 90890-01701This tool is used for when loosening
or tightening the flywheel magneto
securing nut.
Pocket tester
YU-3112-C, 90890-03112 Use this tool to inspect the coil resis-
tance, output voltage and amper-
age.
Timing light
YM-33277-A, 90890-03141 This tool is necessary for checking
ignition timing.
Valve spring compressor
YM-4019, 90890-04019 This tool is needed to remove and
install the valve assemblies. Tool name/Part number How to use Illustration

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SPECIAL TOOLS
Clutch holding tool
YM-91042, 90890-04086 This tool is used to hold the clutch
when removing or installing the
clutch boss securing nut.
Valve guide remover
Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)
YM-4116, 90890-04116
YM-4097, 90890-04097This tool is needed to remove and
install the valve guide.
Valve guide installer
Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)
YM-4117, 90890-04117
YM-4098, 90890-04098This tool is needed to install the
valve guide.
Valve guide reamer
Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)
YM-4118, 90890-04118
YM-4099, 90890-04099This tool is needed to rebore the
new valve guide.
Rotor puller
YM-4142, 90890-04142This tool is used to remove the fly-
wheel magneto.
Crankcase separating tool
YU-A9642
90890-04152These tool is used to remove the
crankshaft from either case. Tool name/Part number How to use Illustration

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SPECIAL TOOLS
Dynamic spark tester
YM-34487
Ignition checker
90890-06754This instrument is necessary for
checking the ignition system compo-
nents.
Vacuum/pressure pump gauge set
YB-35956-A, 90890-06756This tool is used to check the air in-
duction system.
Digital tachometer
YU-39951-B, 90890-06760This tool is needed for observing en-
gine rpm.
YAMAHA Bond No. 1215 (ThreeB-
ond
® No. 1215)
90890-85505This sealant (Bond) is used for
crankcase mating surface, etc. Tool name/Part number How to use Illustration

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CONTROL FUNCTIONS
CONTROL FUNCTIONS
MAIN SWITCH
Functions of the respective switch po-
sitions 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 forget-
ting to turn it off. This light functions
as follows.
• It lights up with the main switch
"ON".
• It goes out when the engine in-
creases its speed after being start-
ed.
• It lights up again when the engine is
stopped.
If the indicator light will not light up
with the main switch "ON", it shows a
lack of the battery voltage. Recharge
the battery.
ENGINE STOP SWITCH
The engine stop switch "1" is located
on the left handlebar. Continue push-
ing the engine stop switch till the en-
gine 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.CLUTCH LEVER
The clutch lever "1" is located on the
left handlebar; it disengages or en-
gages the clutch. Pull the clutch lever
to the handlebar to disengage the
clutch, and release the lever to en-
gage the clutch. The lever should be
pulled rapidly and released slowly for
smooth starts.
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.
KICKSTARTER CRANK
Rotate the kickstarter crank "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 crank
so the engine can be started in any
gear if the clutch is disengaged. In
normal practices, however, shift to
neutral before starting.
THROTTLE GRIP
The throttle grip "1" is located on the
right handlebar; it accelerates or de-
celerates the engine. For accelera-
tion, turn the grip toward you; for
deceleration, turn it away from you.FRONT BRAKE LEVER
The front brake lever "1" is located on
the right handlebar. Pull it toward the
handlebar to activate the front brake.
REAR BRAKE PEDAL
The rear brake pedal "1" is located on
the right side of the machine. Press
down on the brake pedal to activate
the rear brake.
FUEL COCK
The fuel cock supplies fuel from the
tank to carburetor and also filters the
fuel. The fuel cock has the three posi-
tions:
OFF:
With the lever in this position, fuel will
not flow. Always return the lever to
this position when the engine is not
running.
ON:
With the lever in this position, fuel
flows to the carburetor. Normal riding
is done with the lever in this position.
RES:
With the lever in this position fuel
flows to the carburetor from the re-
serve section of the fuel tank after the
main supply of the fuel has been de-
pleted. Normal riding is possible with
the lever is in this position, but it is
recommended to add fuel as soon as
possible.

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MULTI-FUNCTION DISPLAY
COLD STARTER KNOB
When cold, the engine requires a
richer air-fuel mixture for starting. A
separate starter circuit, which is con-
trolled by the cold starter knob "1",
supplies this mixture. Pull the cold
starter knob out to open the circuit for
starting. When the engine has
warmed up, push it in to close the cir-
cuit.
HOT STARTER LEVER
The hot starter lever "1" is used when
starting a warm engine. Use the hot
starter lever when starting the engine
again immediately after it was
stopped (the engine is still warm).
Pulling the hot starter lever injects
secondary air to thin the air-fuel mix-
ture temporarily, allowing the engine
to be started more easily.
SIDESTAND
This sidestand "1" is used to support
only the machine when standing or
transporting it.
• Never apply additional force to
the sidestand.
• Hold up the sidestand before
starting out.
MULTI-FUNCTION DISPLAY
Be sure to stop the machine before
making any setting changes to the
multi-function display.
The multi-function display is
equipped with the following:
BASIC MODE:
• Speedometer
•Clock
• Two tripmeters (which shows the
distance that has been traveled
since it was last set to zero)
RACE MODE:
• Timer (which shows the time that
has been accumulated since the
start of timer measurement)
• Tripmeter (which shows the accu-
mulated travel distance in timer
measurement)
• Change tripmeter digits (capable of
change to any given ones)
DESCRIPTION
Operation buttons:
1. Select button "SLCT 1"
2. Select button "SLCT 2"
3. Reset button "RST"
Screen display:
4. Tripmeter indicator
5. Tripmeter indicator
6. Timer indicator
7. Clock/Timer
8. Speedometer
9. Odometer/Tripmeter
The operation buttons can be pushed
in the following two manners:
Short push: Push the button. ( )
Long push: Push the button for 2 sec-
onds or more. ( )
BASIC MODE
Changing speedometer display
(for U.K.)
1. Push the "SLCT2" button for 2
seconds or more to change the
speedometer units. The speed-
ometer display will change in the
following order:
MPH→km/h→MPH.Setting the time
1. Push the "SLCT1" button for 2
seconds or more to enter the time
setting mode.
2. Push the "RST" button to change
the display for time indication.
The display will change in the fol-
lowing order:
Hour→Minute→Second→Hour.
The digits capable of setting go on
flashing.
3. Push the "SLCT1" button (plus) or
"SLCT2" button (minus) and
change the time. A long push on
the button will fast-forward the
time.
4. To end the setting, push the
"RST" button for 2 seconds or
more.
• In a 30-second absence of button
operation, the setting will come to
an end with the indicated time.
• To reset the seconds, push the
"SLCT1" button or "SLCT2" button.
Changing odometer and tripmeter
A/B (TRIP A/B)
1. Push the "SLCT2" button to
change the tripmeter display. The
display will change in the follow-
ing order:
Odometer →TRIP A→TRIP B→
TRIP A→Odometer.

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MULTI-FUNCTION DISPLAY
To reset the digits, select the tripme-
ter involved and push the "RST" but-
ton for 2 seconds or more.
CHANGEOVER TO BASIC MODE/
RACE MODE
• Measurement using the timer func-
tion can be made in RACE MODE.
• Indicator will light up as an
identifier that shows RACE MODE
has been selected.
• RACE MODE cannot display the
functions as in BASIC MODE.
• Changeover to RACE MODE forc-
es the digits for tripmeter A (TRIP
A) in BASIC MODE to be reset.
Changeover from BASIC MODE to
RACE MODE
1. Push the "SLCT1" button and
"SLCT2" button for 2 seconds or
more at the same time to change
over to RACE MODE.
Changeover to RACE MODE will put
manual start measurement on stand-
by causing and to flash. (For
manual start, refer to "Putting mea-
surement on standby" in "RACE
MODE".)
Returning to BASIC MODE from
RACE MODE
It is possible to return to BASIC
MODE with timer measurement at a
stop.
1. Check that the timer is not in op-
eration. If the timer is in operation,
stop the timer by pushing the
"SLCT1" button and "SLCT2" but-
ton at the same time.
2. Push the "SLCT1" button and
"SLCT2" button for 2 seconds or
more at the same time to change
over to BASIC MODE.
RACE MODE
Putting measurement on standby
Starting measurement consists of the
following two starts, either of which
can be selected.
• Manual start
Starting measurement by the rider
himself operating the button. (A long
push on the "SLCT2" button will put
measurement on standby.)
• Auto start
Starting timer measurement automat-
ically on detection of the movement of
the machine. (A long push on the
"SLCT1" button will put measurement
on standby.)
Manual start
Initial setting at changeover to RACE
MODE will remain for manual start.
1. Check that changeover to RACE
MODE has been made. (Refer to
"Changeover from BASIC MODE
to RACE MODE".)
When the machine is made ready for
a run by manual start, and will
start flashing.
2. Start timer measurement by
pushing the "RST" button.
3. When stopping timer measure-
ment, pushing the "SLCT1" but-
ton and "SLCT2" button at the
same time.
If the machine is run while timer mea-
surement is not made, no change will
occur to the digit in tripmeter A (TRIP
A).
4. To resume the measurement,
again push the "SLCT1" button
and "SLCT2" button at the same
time.
Auto start
1. Check that changeover has been
made to RACE MODE. (Refer to
"Changeover from BASIC MODE
to RACE MODE".)
2. Make the machine ready for a run
by pushing the "SLCT1" button for
2 seconds or more.
When the measurement is made
ready for a run by auto start, and
will start flashing. Timer display
will turn on scrolling from left to right.
3. Run the machine and start timer
measurement.
4. To stop timer measurement,
pushing the "SLCT1" button and
"SLCT2" button at the same time.