dimensions YAMAHA WR 450F 2009 Owners Manual

2-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name: WR450FY (USA, CDN, AUS, NZ)
WR450F (EUROPE, ZA)
Model code number: 5TJN (USA)
5TJP (CDN)
5TJR (EUROPE)
5TJS (AUS, NZ, ZA)
Dimensions: USA, CDN, ZA EUROPE AUS, NZ
Overall length 2,175 mm (85.63
in) 2,200 mm (86.61
in)2,190 mm (86.22
in)
Overall width 825 mm (32.48 in)←←
Overall height 1,295 mm (50.98
in)1,305 mm (51.38
in)1,300 mm (51.18
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)1,485 mm (58.46
in)
Minimum ground clearance 365 mm (14.37 in) 375 mm (14.76 in) 370 mm (14.57 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 USA and CDN)
Yamalube 4, SAE10W-40 or SAE20W-50
Yamalube 4-R, SAE10W-50
API service SG type or higher,
JASO standard MA

2-4
MAINTENANCE SPECIFICATIONS
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ----
Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ----
Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003
in)
Cam dimensions
Intake "A" 30.100–30.200 mm (1.1850–1.1890 in) 30.000 mm
(1.1811 in)
Intake "B" 22.450–22.550 mm (0.8839–0.8878 in) 22.350 mm
(0.8799 in)
Exhaust "A" 30.200–30.300 mm (1.1890–1.1929 in) 30.100 mm
(1.1850 in)
Exhaust "B" 22.450–22.550 mm (0.8839–0.8878 in) 22.350 mm
(0.8799 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
Timing chain:
Timing chain type/No. of links 98XRH2010-118M/118 ----
Timing chain adjustment method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold)
IN 0.10–0.15 mm (0.0039–0.0059 in) ----
EX 0.20–0.25 mm (0.0079–0.0098 in) ----
Valve dimensions:
"A" head diameter (IN) 26.9–27.1 mm (1.0591–1.0669 in) ----
"A" head diameter (EX) 27.9–28.1 mm (1.0984–1.1063 in) ----Item Standard Limit

2-6
MAINTENANCE SPECIFICATIONS
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)
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:Item Standard Limit

2-7
MAINTENANCE SPECIFICATIONS
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 ----
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 ----Item Standard Limit

6-25
HANDLEBAR
5. Install:
• Right grip "1"
•Collar "2"
Apply the adhesive on the tube
guide "3".
• Before applying the adhesive, wipe
off grease or oil on the tube guide
surface "a" with a lacquer thinner.
• Install the grip to the tube guide so
that the grip match mark "b" and
tube guide slot "c" form the angle as
shown.
6. Install:
• Grip cap cover "1"
• Throttle grip "2"
Apply the lithium soap base grease
on the throttle grip sliding surface.
7. Install:
• Throttle cables "1"
To tube guide "2".
Apply the lithium soap base grease
on the throttle cable end and tube
guide cable winding portion.
8. Install:
• Throttle cable cap "1"
• Screw (throttle cable cap) "2"
After tightening the screws, check
that the throttle grip "3" moves
smoothly. If it does not, retighten
the bolts for adjustment.
9. Install:
• Grip cap cover "1"
• Cover (throttle cable cap) "2"
10. Install:
• Start switch "1"
• Brake master cylinder "2"
• Brake master cylinder bracket "3"
• Bolt (brake master cylinder brack-
et) "4"
•Clamp "5"
• The start switch and brake master
cylinder bracket should be installed
according to the dimensions
shown.
• Install the bracket so that the arrow
mark "a" faces upward.• First tighten the bolt on the upper
side of the brake master cylinder
bracket, and then tighten the bolt on
the lower side.
11. Install:
• Engine stop switch "1"
• Clutch lever holder "2"
• Bolt (clutch lever holder) "3"
• Hot starter lever holder "4"
• Bolt (hot starter lever holder) "5"
• Clamp "6"
• The engine stop switch, clutch lever
holder and clamp should be in-
stalled according to the dimensions
shown.
• Pass the engine stop switch lead in
the middle of the clutch lever hold-
er.
Screw (throttle cable
cap):
4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (brake master cylin-
der bracket):
9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (clutch lever holder):
4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (hot starter lever
holder):
4 Nm (0.4 m•kg, 2.9
ft•lb)