light YAMAHA WR 450F 2009 User Guide

2-15
TIGHTENING TORQUES
△Driven sprocket and wheel hub M8 × 1.25 6 50 5.0 36
△Nipple (spoke) — 72 3 0.3 2.2
△Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2
△Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
△Engine upper bracket and frame M10 × 1.25 4 55 5.5 40
△Engine lower bracket and frame M8 × 1.25 4 34 3.4 24
△Engine and engine bracket (lower) M10 × 1.25 1 53 5.3 38
△Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
△Engine and frame (lower) M10 × 1.25 1 53 5.3 38
△Engine guard M6 × 1.0 3 7 0.7 5.1
Regulator mounting M6 × 1.0 2 7 0.7 5.1
△Pivot shaft and nut M16 × 1.5 1 85 8.5 61
△Relay arm and swingarm M14 × 1.5 1 70 7.0 50
△Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
△Connecting rod and frame M14 × 1.5 1 80 8.0 58
△Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
△Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
△Rear frame and frame (upper) M8 × 1.25 1 38 3.8 27
△Rear frame and frame (lower) M8 × 1.25 2 32 3.2 23
△Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Drive chain tensioner mounting (upper) M8 × 1.25 1 16 1.6 11
Drive chain tensioner mounting (lower) M8 × 1.25 1 16 1.6 11
Chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
△Fuel tank mounting M6 × 1.0 2 9 0.9 6.5
△Fuel tank and fuel cock M6 × 1.0 2 4 0.4 2.9
Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
△Seat mounting M8 × 1.25 2 23 2.3 17
△Side cover mounting M6 × 1.0 2 7 0.7 5.1
△Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
△Air scoop and radiator panel (lower) M6 × 1.0 2 6 0.6 4.3
△Front fender mounting M6 × 1.0 4 7 0.7 5.1
△Rear fender mounting(front) M6 × 1.0 2 7 0.7 5.1
△Rear fender mounting (rear) M6 × 1.0 2 11 1.1 8.0
Multi-function display bracket mounting M6 × 1.0 2 7 0.7 5.1
Multi-function display mounting M5 × 0.8 2 4 0.4 2.9
Plate 1 and protector M5 × 0.8 2 4 0.4 2.9
Plate 2 and protector — 2 0.5 0.05 0.36
Speed sensor lead holder and under bracket M6 × 1.0 1 13 1.3 9.4
Headlight body and headlight unit — 2 1 0.1 0.7Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb

2-16
TIGHTENING TORQUES
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen
the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
ELECTRICAL
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).
△Headlight mounting (left and right) M6 × 1.0 2 7 0.7 5.1
Taillight mounting — 3 1 0.1 0.7
Taillight lead clamp and rear fender — 3 0.5 0.05 0.36
△Catch tank (upper) M6 × 1.0 1 16 1.6 11
△Catch tank (lower) M6 × 1.0 1 7 0.7 5.1
△Footrest bracket and frame M10 × 1.25 4 55 5.5 40
Sidestand mounting M10 × 1.25 1 25 2.5 18Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
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 10 1.0 7.2
Rotor M12 × 1.25 1 Refer to TIP.
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
Pickup coil M6 × 1.0 2 10 1.0 7.2

2-21
CABLE ROUTING DIAGRAM
A. Insert the end of the fuel tank
breather hose into the hole in
the steering stem.
B. Fasten the throttle cable, hot
starter cable and rectifier/regula-
tor lead onto the frame. Locate
the clamp ends under the throt-
tle cable, and after clamping,
leave the other end as is and do
not cut it.
C. Fasten the diode (at the mark-
ing), throttle cable and hot start-
er cable onto the frame. Locate
the clamp end facing toward the
lower right of the frame and with
the tie end facing downward.
D. Fasten the wire harness, throttle
position sensor lead and clutch
cable onto the frame. Pass the
clamp through the hole in the
stay (air cut-off valve). Locate
the clamp end facing toward the
lower side of the frame and cut
off the tie end.
E. Pass the carburetor breather
hoses, carburetor overflow hose
and catch tank breather hose
between the connecting rod and
cross tube (frame).
F. Pass the neutral switch lead on
the inside of the engine bracket.
G. Fasten the neutral switch lead
and AC magneto lead onto the
frame. Locate the clamp end
facing toward the outside of the
frame and tie end facing toward
the rear of the frame.
H. Fasten the AC magneto lead
and neutral switch lead onto the
frame. Locate the clamp end
facing toward the rear of the
frame and cut off the tie end.
I. Pass the neutral switch lead and
AC magneto lead on the inside
of the wire harness.
J. Fasten the AC magneto lead
and neutral switch lead onto the
frame.
K. Pass the wire harness through
the cable guide.
L. Locate the couplers in the frame
recess.
M. Pass the carburetor breather
hoses, carburetor overflow hose
and catch tank breather hose so
that the hoses do not contact the
rear shock absorber.
N. Secure the coupler by pushing it
into the hole in the headlight
unit.
O. Fasten the throttle position sen-
sor lead and the hot starter ca-
ble.P. Locate the clamp between the
hot starter cable protector and
rubber cap.

2-23
CABLE ROUTING DIAGRAM
1. Brake master cylinder
2. Brake hose holder
3. Brake hoseA. Install the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the brake caliper.
B. Pass the brake hose into the
brake hose holders.
C. If the brake hose contacts the
spring (rear shock absorber),
correct its twist.D. Install the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the brake master cylin-
der.

2-24
CABLE ROUTING DIAGRAM
1. Clamp
2. Positive battery lead
3. Battery
4. Negative battery lead
5. Taillight coupler
6. CDI unit coupler (6-pin)
7. CDI unit coupler (3-pin)
8. CDI unit coupler (6-pin)A. Fasten the wire harness to the
upper engine bracket (left side).
Locate the clamp end facing to-
ward the upper side of the frame
with the tie end cut off on the in-
side of the frame.B. Fasten the wire harness to the
upper engine bracket (left side).
Locate the clamp end facing to-
ward the upper side of the frame
with the tie end cut off on the in-
side of the frame. Clamp the
wire harness at the marking.
C. Pass the starter motor lead
through the hole in the relay
holder.
D. Fit the cover securely.

2-25
CABLE ROUTING DIAGRAM
E. Connect the wire harness to the
starter relay.
F. Fasten the catch tank breather
hose and catch tank hose to the
rear frame. Clamp them close to
where they are joined to the
frame. Fasten the pipe tightly
enough not to crush it. Locate
the clamp end facing toward the
rear of the frame with the tie end
facing downward.
G. Fasten the (three) CDI unit leads
and taillight lead to the rear
frame. Locate the clamp end
facing toward the upper side of
the frame and cut off the tie end.
H. Connect the negative battery
lead to the battery negative ter-
minal.
I. Connect the negative battery
lead to the wire harness.
J. Fasten the wire harness to the
rear frame. Locate the clamp
end facing toward the upper side
of the frame and the tie end to-
ward the inside of the frame.
Clamp the wire harness at the
marking.
K. Pass the wire harness, starter
relay lead, starting circuit cut-off
relay lead and negative battery
lead through the hole in the relay
holder.
L. Fasten the (three) CDI unit leads
and taillight lead to the rear
frame. Locate the clamp end
facing toward the lower side of
the frame and cut off the tie end.
M. Fasten the taillight lead to the
rear frame. Locate the clamp
end facing toward the upper side
of the frame and cut off the tie
end.
N. Do not allow the taillight lead to
slacken.
O. Locate the CDI unit lead be-
tween the CDI unit and rear
fender.
P. Locate the CDI unit coupler in
the clearance between the up-
per side of the CDI unit and low-
er side of the catch tank stay.
Q. Locate the CDI unit lead be-
tween the CDI unit and rear
frame.

2-26
CABLE ROUTING DIAGRAM
1. Throttle cable
2. Clamp
3. Brake hose
4. Clutch cable
5. Hose guide
6. Main switch coupler
7. Wire harness
8. Headlight coupler
9. Hot starter cable
10. Multi-function display bracket
11. Main switch12. Upper bracket
13. Clutch switch coupler
14. Engine stop switch coupler
15. Multi-function display coupler
16. Start switch coupler
17. Speed sensor coupler
18. Speed sensor leadA. Fasten the start switch lead to
the handlebar with the plastic
bands.
B. Fasten the engine stop switch
lead and clutch switch lead to
the handlebar with the plastic
bands.
C. Pass the brake hose through
the hose guides.

3-2
GENERAL MAINTENANCE AND LUBRICATION CHART
(For Canada)
GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada)
No. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER
READINGS600 mi
(1,000
km) or 1
month1,800 mi
(3,000
km) or 3
months3,000 mi
(5,000
km) or 6
months
1 ClutchCheck operation.
√√√
Adjust or replace cable.
2 * Cooling systemCheck hoses for cracks of damage.
√√√
Replace if necessary.
Replace with ethylene glycol anti-freeze cool-
ant every 1 year.Every 1 year
3 * Spark arrester Clean.√
4 * Front brakeCheck operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
5 * Rear brakeCheck operation, fluid level, and for fluid leak-
age.
√√√
Replace brake pads if necessary.
Replace brake fluid every 1 year. Every 1 year
6 * Brake hosesCheck for cracks or damage.√√
Replace. Every 4 years
7 * WheelsCheck runout, spoke tightness and for dam-
age.
√√√
Tighten spokes if necessary.
8*TiresCheck tread depth and for damage.
√√√ Replace if necessary.
Check air pressure.
Correct if necessary.
9 * Wheel bearingsCheck bearings for smooth operation.
√√√
Replace if necessary.
10 * Swingarm pivot bearingsCheck bearing assemblies for looseness.
√√√
Moderately repack with lithium-soapbased
grease.
11 Drive chainCheck chain slack/alignment and condition.
Every ride
Adjust and lubricate chain with a special O-ring
chain lubricant thoroughly.
12 * Steering bearingsCheck bearing assemblies for looseness.
√√√ Moderately repack with lithium-soapbased
grease every 1,200 mi (2,000 km) or 12
months (whichever comes first).
13Brake and clutch lever pivot
shaftsApply lithium-soap-based grease (all-purpose
grease) lightly.√√√
14 Brake pedal pivot shaftsApply lithium-soap-based grease (all-purpose
grease) lightly.√√√
3

3-3
MAINTENANCE INTERVALS FOR COMPETITION USE
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid
levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
MAINTENANCE INTERVALS FOR COMPETITION USE
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.
15 Sidestand pivotCheck operation.
√√√
Apply lithium-soap-based grease (all-purpose
grease) lightly.
16 * Front forkCheck operation and for oil leakage.
√√
Replace if necessary.
17 * Shock absorber assemblyCheck operation and for oil leakage.
√√
Replace if necessary.
18 * Rear suspension link pivots Apply molybdenum disulfide grease lightly.√√
19 * Control cablesApply Yamaha chain and cable lube or engine
oil 10W-30 thoroughly.√√√
20 * Throttle grip housing and cableCheck operation and free play.
√√√ Adjust the throttle cable free play if necessary.
Lubricate the throttle grip housing and cable.
21 * Chassis fastenersCheck all chassis fitting and fasteners.
√√√
Correct if necessary.
22 Battery Check terminal for looseness and corrosion.√√ No. ITEM CHECKS AND MAINTENANCE JOBSINITIALODOMETER
READINGS
600 mi
(1,000
km) or 1
month1,800 mi
(3,000
km) or 3
months3,000 mi
(5,000
km) or 6
months
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.

3-8
ENGINE
ENGINE
REMOVING THE SEAT, FUEL TANK AND SIDE COVERS
Order Part name Q'ty Remarks
Turn the fuel cock to "OFF".
Disconnect the fuel hose.
1Seat 1
2 Air scoop (left and right) 2
3 Bolt (fuel tank) 2
4 Fuel tank 1
5 Left side cover 1 Open the air filter case cover.
6 Right side cover 1 Refer to removal section.
7 Headlight coupler 1
8 Headlight 1