length YAMAHA WR 450F 2008 Owners Manual

FOREWORD
INTRODUCTION
Congratulations on your purchase of
a Yamaha WR series. This model is
the culmination of Yamaha's vast ex-
perience in the production of paceset-
ting racing machines. It represents
the highest grade of craftsmanship
and reliability that have made Yama-
ha a leader.
This manual explains operation, in-
spection, basic maintenance and tun-
ing of your machine. If you have any
questions about this manual or your
machine, please contact your Yama-
ha dealer.
Yamaha continually seeks advance-
ments in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your machine and this manual. If you
have any questions concerning this
manual, please consult your Yamaha
dealer.
PLEASE READ THIS MANUAL
CAREFULLY AND COMPLETELY
BEFORE OPERATING THIS MA-
CHINE. DO NOT ATTEMPT TO OP-
ERATE THIS MACHINE UNTIL YOU
HAVE ATTAINED A SATISFACTO-
RY KNOWLEDGE OF ITS CON-
TROLS AND OPERATING
FEATURES AND UNTIL YOU HAVE
BEEN TRAINED IN SAFE AND
PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND
CAREFUL MAINTENANCE,
ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU
SAFETY ENJOY THE CAPABILI-
TIES AND THE RELIABILITY OF
THIS MACHINE.
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means AT-
TENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!Failure to follow WARNING instruc-
tions could result in severe injury or
death to the machine operator, a by-
stander, or a person inspecting or re-
pairing the machine.
A CAUTION indicates special pre-
cautions that must be taken to avoid
damage to the machine.
A NOTE provides key information to
make procedures easier or clearer.
IMPORTANT NOTICE
THIS MACHINE IS DESIGNED
STRICTLY FOR COMPETITION
USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine
to be operated on any public street,
road, or highway. Off-road use on
public lands may be illegal. Please
check local regulations before riding.
1. THIS MACHINE IS TO BE OP-
ERATED BY AN EXPERI-
ENCED RIDER ONLY.
Do not attempt to operate this
machine at maximum power
until you are totally familiar
with its characteristics.
2. THIS MACHINE IS DESIGNED
TO BE RIDDEN BY THE OP-
ERATOR ONLY.
Do not carry passengers on
this machine.
3. ALWAYS WEAR PROTEC-
TIVE APPAREL.
When operating this ma-
chine, always wear an ap-
proved helmet with goggles
or a face shield. Also wear
heavy boots, gloves, and pro-
tective clothing. Always wear
proper fitting clothing that
will not be caught in any of
the moving parts or controls
of the machine.
4. ALWAYS MAINTAIN YOUR
MACHINE IN PROPER
WORKING ORDER.
For safety and reliability, the
machine must be properly
maintained. Always perform
the pre-operation checks in-
dicated in this manual. Cor-
recting a mechanical problem
before you ride may prevent
an accident.
5. GASOLINE IS HIGHLY FLAM-
MABLE.
Always turn off the engine
while refueling. Take care to
not spill any gasoline on the
engine or exhaust system.
Never refuel in the vicinity of
an open flame, or while
smoking.
6. GASOLINE CAN CAUSE IN-
JURY.
If you should swallow some
gasoline, inhale excess gaso-
line vapors, or allow any gas-
oline to get into your eyes,
contact a doctor immediately.
If any gasoline spills onto
your skin or clothing, imme-
diately wash skin areas with
soap and water, and change
your clothes.
7. ONLY OPERATE THE MA-
CHINE IN AN AREA WITH AD-
EQUATE VENTILATION.
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 mon-
oxide, which by itself is odor-
less and colorless. Carbon
monoxide is a dangerous gas
which can cause uncon-
sciousness or can be lethal.
8. PARK THE MACHINE CARE-
FULLY; TURN OFF THE EN-
GINE.
Always turn off the engine if
you are going to leave the
machine. Do not park the ma-
chine on a slope or soft
ground as it may fall over.

2-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name: WR450FX (CDN, AUS, NZ)
WR450F (EUROPE, ZA)
Model code number: 5TJK (CDN)
5TJL (EUROPE)
5TJM (AUS, NZ, ZA)
Dimensions: CDN, ZA AUS, NZ EUROPE
Overall length 2,175 mm (85.63
in) 2,190 mm (86.22
in)2,200 mm (86.61
in)
Overall width 825 mm (32.48 in)←←
Overall height 1,295 mm (50.98
in)1,300 mm (51.18
in)1,305 mm (51.38
in)
Seat height 980 mm (38.58 in) 990 mm (38.98 in)←
Wheelbase 1,485 mm (58.46
in)←1,500 mm (59.06
in)
Minimum ground clearance 365 mm (14.37 in) 370 mm (14.57 in) 375 mm (14.76 in)
Dry weight:
Without oil and fuel 112.5 kg (248.0 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 449 cm
3 (15.8 Imp oz, 15.2 US oz)
Bore × stroke 95.0 × 63.4 mm (3.74 × 2.50 in)
Compression ratio 12.3 : 1
Starting system Kick and electric starter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For CDN)
Yamalube 4, SAE10W30 or SAE20W40
Yamalube 4-R, SAE10W50
API service SG type or higher,
JASO standard MA

2-6
MAINTENANCE SPECIFICATIONS
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve spring:
Free length (IN) 39.46 mm (1.55 in) 38.46 mm (1.51
in)
Free length (EX) 37.61 mm (1.48 in) 36.61 mm (1.44
in)
Set length (valve closed) (IN) 27.87 mm (1.10 in) ----
Set length (valve closed) (EX) 28.38 mm (1.12 in) ----
Compressed force (installed) (IN) 130.2–149.8 N at 27.87 mm (13.28–15.28
kg at 27.87 mm, 29.27–33.68 lb at 1.10 in)----
Compressed force (installed) (EX) 123.1–141.7 N at 28.38 mm (12.55–14.45
kg at 28.38 mm, 27.67–31.85 lb at 1.12 in)----
Tilt limit* (IN) ---- 2.5°/1.7 mm
(2.5°/0.067 in)
Tilt limit* (EX) ---- 2.5°/1.6 mm
(2.5°/0.063 in)
Direction of winding (top view) (IN) Clockwise ----
Direction of winding (top view) (EX) Clockwise ----
Piston:
Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in) 0.1 mm (0.004
in)
Piston size "D" 94.965–94.980 mm (3.7388–3.7394 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

2-8
MAINTENANCE SPECIFICATIONS
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: CDN, ZA, AUS, NZ EUROPE
I. D. mark 5TJE E0 5TJL L0 ----
Main jet (M.J) #162 #160 ----
Main air jet (M.A.J) ø2.0←----
Jet needle (J.N) NFNT NNHU ----
Cutaway (C.A) 1.5←----
Pilot jet (P.J) #45 #48 ----
Pilot air jet (P.A.J) #70←----
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) #60←----
Float height (F.H) 8 mm (0.31 in)←----
Engine idle speed 1,750–1,950 r/min←----
Intake vacuum 34.8–40.1 kPa
(261–301 mmHg,
10.28–11.85 inHg)←----
Hot starter lever free play 3–6 mm (0.12–0.24
in)←---- Item Standard Limit

2-10
MAINTENANCE SPECIFICATIONS
CHASSIS
Item Standard Limit
Steering system:
Steering bearing typeTaper roller bearing ----
Front suspension: CDN AUS, NZ, ZA, EUROPE
Front fork travel 300 mm (11.8 in)←----
Fork spring free length 460 mm (18.1 in)←455 mm (17.9
in)
Spring rate, STD K = 4.5 N/mm (0.459 kg/
mm, 25.7 lb/in)←----
Optional spring/spacer Yes←----
Oil capacity 648 cm
3 (22.8 lmp oz,
21.9 US oz)655 cm3 (23.1 lmp oz,
22.1 US oz)----
Oil level 132 mm (5.20 in) 125 mm (4.92 in) ----
(From top of outer tube with inner
tube and damper rod fully compressed without
spring.)95–150 mm (3.74–5.91
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: CDN, ZA, AUS, NZ EUROPE
Shock absorber travel 130 mm (5.12 in)←----
Spring free length 260 mm (10.24 in)←----
Fitting length 252.5 mm (9.94 in) 251.5 mm (9.90 in) ----
238.5–258.5 mm (9.39–
10.18 in)←----
Spring rate, STD K = 54.0 N/mm (5.50 kg/
mm, 308.0 lb/in)←----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa (10 kg/cm
2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04
in)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel typeSpoke 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)

2-11
MAINTENANCE SPECIFICATIONS
ELECTRICALDrive 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)10 mm (0.39 in) ----
Clutch lever free play (lever end) 8–13 mm (0.31–0.51 in) ----
Throttle grip free play3–5 mm (0.12–0.20 in) ---- Item Standard Limit
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI: CDN, ZA, AUS,NZ EUROPE
Pickup coil resistance (color) 248–372 Ωat 20 °C
(68 °F) (White–Red)←----
CDI unit-model/manufacturer 5TJ-F0 5TJ-L0 ----
Ignition coil:
Model/manufacturer 5TA-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08–0.10 Ωat 20 °C (68 °F) ----
Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ----

2-12
MAINTENANCE SPECIFICATIONS
Charging system:
System type AC magneto ----
Model (stator)/manufacturer 5TJ 50/YAMAHA ----
Normal output 14 V/120 W at 5,000 r/min ----
Charging coil resistance (color) 0.288–0.432 Ω at 20 °C (68 °F) (White–
Ground)----
Lighting coil resistance (color) 0.224–0.336 Ω at 20 °C (68 °F) (Yellow–
Ground)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacturer SH770AA/SHINDENGEN ----
Regulated voltage (AC) 12.5–13.5 V ----
Regulated voltage (DC) 14.0–15.0 V ----
Rectifier capacity (AC) 12 A ----
Rectifier capacity (DC) 8 A ----
Electric starting system:
Type Constant mesh ----
Starter motor:
Model/manufacturer 5UM20/YAMAHA ----
Operation voltage 12 V ----
Output 0.48 kW ----
Armature coil resistance 0.0117–0.0143 Ω at 20 °C (68 °F) ----
Brush overall length 7 mm (0.28 in) 3.5 mm (0.14
in)
Brush quantity 2 pcs. ----
Spring force 3.92–5.88 N (400–600 g, 14.1–21.2 oz) ----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65
in)
Mica undercut (depth) 1.5 mm (0.06 in) ----
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 ----Item Standard Limit

2-18
TIGHTENING TORQUES
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for stan-
dard fasteners with standard I.S.O.
pitch threads. Torque specifications
for special components or assem-
blies are included in the applicable
sections of this book. To avoid
warpage, tighten multi-fastener as-
semblies in a crisscross fashion, in
progressive stages, until full torque is
reached. Unless otherwise specified,
torque specifications call for clean,
dry threads. Components should be
at room temperature.A. Distance between flats
B. Outside thread diameter
DEFINITION OF UNITS
A
(Nut)B
(Bolt
)TORQUE SPECIFI-
CATION
Nm m•kg ft•lb
10
mm6 mm 6 0.6 4.3
12
mm8 mm 15 1.5 11
14
mm10
mm30 3.0 22
17
mm12
mm55 5.5 40
19
mm14
mm85 8.5 61
22
mm16
mm130 13 94
Unit Read Definition Measure
mm
millimeter 10-3 meter Length
cmcentimeter 10-2 meter Length
kgkilogram 103 gram Weight
NNewton 1 kg × m/sec2Force
NmNewton meter N × m Torque
m•kgMeter kilogram m × kg Torque
PaPascal N/m2Pressure
N/mmNewton per millimeter N/mm Spring rate
LLiter — Volume or capacity
cm3Cubic centimeter — Volume or capacity
r/minRevolution per minute — Engine speed

3-1
MAINTENANCE INTERVALS
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●●The engine must be cold.
Inspect●Check the valve seats and valve
stems for wear.
Replace●
VALVE SPRINGS
Inspect●Check the free length and the tilt.
Replace●
VALVE LIFTERS
Inspect●Check for scratches and wear.
Replace●
CAMSHAFTS Inspect the camshaft surface.
Inspect●Inspect the decompression system.
Replace●
CAMSHAFT SPROCKETS
Inspect●Check for wear on the teeth and for
damage.
Replace●
PISTON
Inspect●●Inspect crack.
Clean●Inspect carbon deposits and eliminate
them.
Replace●
PISTON RING
Inspect●Check ring end gap.
Replace●●
PISTON PIN
Inspect●
Replace●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean●Change gasket.
CYLINDER
Inspect and clean●Inspect score marks.
Replace●Inspect wear.

3-20
CHASSIS
3. Inspect:
• Brake fluid level
Refer to "CHECKING THE
BRAKE FLUID LEVEL" section.
4. Check:
• Brake pedal operation
A softy or spongy feeling→Bleed
brake system.
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion.
CHECKING THE REAR BRAKE
PAD INSULATOR
1. Remove:
• Brake pad
Refer to "CHECKING AND RE-
PLACING THE REAR BRAKE
PADS" section.
2. Inspect:
• Rear brake pad insulator "1"
Damage→Replace.
CHECKING THE BRAKE FLUID
LEVEL
1. Place the brake master cylinder
so that its top is in a horizontal po-
sition.
2. Inspect:
• Brake fluid level
Fluid at lower level→Fill up.
• Use only designated quality
brake fluid to avoid poor brake
performance.
• Refill with same type and brand
of brake fluid; mixing fluids
could result in poor brake perfor-
mance.
• Be sure that water or other con-
taminants do not enter master
cylinder when refilling.
• Clean up spilled fluid immediate-
ly to avoid erosion of painted
surfaces or plastic parts.
a. Lower level
A. Front
B. Rear
CHECKING THE SPROCKET
1. Inspect:
• Sprocket teeth "a"
Excessive wear→Replace.
Replace the drive sprocket, rear
wheel sprocket and drive chain as a
set.
CHECKING THE DRIVE CHAIN
1. Measure:
• Drive chain length (15 links) "a"
Out of specification→Replace.
• While measuring the drive chain
length, push down on the drive
chain to increase its tension.
• Measure the length between drive
chain roller "1" and "16" as shown.
• Perform this measurement at two or
three different places.
2. Remove:
• Drive chain "1"
Remove the drive chain using a drive
chain cutter "2".
3. Clean:
• Drive chain
Brush off as much dirt as possi-
ble. Then clean the drive chain
using the chain cleaner.
This machine has a drive chain
with small rubber O-rings "1" be-
tween the side plates. Steam
cleaning, high-pressure washes,
certain solvent and kerosene can
damage these O-rings.
4. Inspect:
• O-ring "1" (drive chain)
Damage→Replace the drive
chain.
•Roller "2"
• Side plate "3"
Damage/wear→Replace the
drive chain.
5. Check:
• Drive chain stiffness "a"
Clean and oil the drive chain and
hold as illustrated.
Stiff→Replace the drive chain.
6. Install:
• Chain joint "1"
• O-ring "2"
• Drive chain "3"
• Link plate "4" Recommended brake flu-
id:
DOT #4
Drive chain length (15
links):
: 239.3 mm
(9.42 in)