ECU YAMAHA WR 450F 2010 Owners Manual

• PROPERLY SECURE THE MA-CHINE BEFORE TRANSPORTING
IT.
When transporting the machine in
another vehicle, always be sure it is
properly secured and in an upright
position and that the fuel cock is in
the "OFF" position. Otherwise, fuel
may leak out of the carburetor or
fuel tank.
F.I.M. MACHINE WEIGHTS
(Except for Canada)
Weights of machines without fuel
The minimum weights for motocross
machines are:
for the class 125 cc:
minimum 88 kg (194 lb)
for the class 250 cc:
minimum 98 kg (216 lb)
for the class 500 cc:
minimum 102 kg (225 lb)
In modifying your machine (e.g., for
weight reduction), take note of the
above limits of weight.
HOW TO USE THIS MANUAL
FINDING THE REQUIRED PAGE
1. This manual consists of seven chapters; "General Information",
"Specifications", "Regular inspec-
tion and adjustments", "Tuning",
"Engine", "Chassis" and "Electri-
cal".
2. The table of contents is at the be-
ginning of the manual. Look over
the general layout of the book be-
fore finding then required chapter
and item.
Bend the book at its edge, as
shown, to find the required fore
edge symbol mark and go to a
page for required item and de-
scription. MANUAL FORMAT
All of the procedures in this manual
are organized in a sequential, step-
by-step format. The information has
been complied to provide the me-
chanic with an easy to read, handy
reference that contains comprehen-
sive explanations of all disassembly,
repair, assembly, and inspection op-
erations.
In this revised format, the condition of
a faulty component will precede an
arrow symbol and the course of ac-
tion required will follow the symbol,
e.g.,
•Bearings
Pitting/damage →Replace.

1-9
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.
Spoke nipple wrench
YM-01521, 90980-01521 This tool is used to tighten the
spoke.
Sheave holder
YS-1880-A, 90890-01701 This 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.
Tool name/Part number How to use Illustration

1-10
SPECIAL TOOLS
Valve spring compressor
YM-4019, 90890-04019 This tool is needed to remove and
install the valve assemblies.
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, 90890-04097 This 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, 90890-04098 This 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, 90890-04099 This tool is needed to rebore the
new valve guide.
Rotor puller
YM-4142, 90890-04142 This tool is used to remove the fly-
wheel magneto.
Crankcase separating tool
YU-A9642
90890-04152 These tool is used to remove the
crankshaft from either case.
Tool name/Part number How to use Illustration

1-21
CLEANING AND STORAGE
CLEANING AND STORAGE
CLEANING
Frequent cleaning of your machine
will enhance its appearance, maintain
good overall performance, and ex-
tend the life of many components.
1. Before washing the machine, block off the end of the exhaust
pipe to prevent water from enter-
ing. A plastic bag secured with a
rubber band may be used for this
purpose.
2. If the engine is excessively greasy, apply some degreaser to
it with a paint brush. Do not apply
degreaser to the chain, sprockets,
or wheel axles.
3. Rinse the dirt and degreaser off with a garden hose; use only
enough pressure to do the job.
Do not use high-pressure washers
or steam-jet cleaners since they
cause water seepage and deterio-
ration seals.
4. After the majority of the dirt has
been hosed off, wash all surfaces
with warm water and a mild deter-
gent. Use an old toothbrush to
clean hard-to-reach places.
5. Rinse the machine off immediate- ly with clean water, and dry all
surfaces with a soft towel or cloth.
6. Immediately after washing, re- move excess water from the
chain with a paper towel and lubri-
cate the chain to prevent rust.
7. Clean the seat with a vinyl uphol-
stery cleaner to keep the cover
pliable and glossy.
8. Automotive wax may be applied
to all painted or chromed surfac-
es. Avoid combination cleaner-
waxes, as they may contain abra-
sives.
9. After completing the above, start the engine and allow it to idle for
several minutes. STORAGE
If your machine is to be stored for 60
days or more, some preventive mea-
sures must be taken to avoid deterio-
ration. After cleaning the machine
thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and
the carburetor float bowl.
2. Remove the spark plug, pour a ta-
blespoon of SAE 10W-40 motor
oil in the spark plug hole, and re-
install the plug. With the engine
stop switch pushed in, kick the en-
gine over several times to coat the
cylinder walls with oil.
3. Remove the drive chain, clean it thoroughly with solvent, and lubri-
cate it. Reinstall the chain or store
it in a plastic bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the
wheels off the ground.
6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture
from entering.
7. If the machine is to be stored in a humid or salt-air environment,
coat all exposed metal surfaces
with a film of light oil. Do not apply
oil to rubber parts or the seat cov-
er.
Make any necessary repairs before
the machine is stored.

2-22
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 under the throttle ca-
ble on the right side of the frame,
and face its ends, as well as the
tie ends, downward.
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.

2-26
CABLE ROUTING DIAGRAM
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.
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.

2-28
CABLE ROUTING DIAGRAM
A. 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.
D. Secure the coupler by inserting
it into the multi-function display
bracket.
E. Pass the throttle cables, clutch
cable and hot starter cable be-
tween the upper bracket and
multi-function display bracket.
F. Fasten the multi-function display
leads to the bracket. Cut off the
tie end.
G. Secure the coupler by pushing it
into the hole in the multi-function
display bracket.
H. Secure the wire harness clip by
pushing it into the hole in the
multi-function display bracket on
the inside.
I. Fasten the main switch lead
(wire harness side) to the multi-
function display bracket. Locate
the clamp end facing toward the
lower side of the frame and cut
off the tie end.
J. Pass the speed sensor lead
through the guide on the outside
of the front fork.

3-26
CHASSIS
ADJUSTING THE REAR SHOCK
ABSORBER HIGH COMPRESSION
DAMPING FORCE
1. Adjust:
• High compression damping force
By turning the adjuster "1".
• STANDARD POSITION:
This is the position which is back
by the specific number of turns
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the adjuster body.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
CHECKING THE TIRE PRESSURE
1. Measure:
• Tire pressure
Out of specification→Adjust.
• Check the tire while it is cold.
• Loose bead stoppers allow the tire
to slip off its position on the rim
when the tire pressure is low.
• A tilted tire valve stem indicates that
the tire slips off its position on the
rim.
• If the tire valve stem is found tilted,
the tire is considered to be slipping
off its position. Correct the tire posi-
tion.
CHECKING AND TIGHTENING THE
SPOKES
The following procedure applies to all
of the spokes.
1. Check:
• Spokes
Bend/damage→Replace.
Loose spoke→Retighten.
Tap the spokes with a screw-
driver.
A tight spoke will emit a clear, ringing
tone; a loose spoke will sound flat.
2. Tighten:
• Spokes
(with a spoke nipple wrench "1")
Be sure to retighten these spokes be-
fore and after break-in.
CHECKING THE WHEELS
1. Inspect:
• Wheel runout
Elevate the wheel and turn it.
Abnormal runout→ Replace.
2. Inspect:
• Bearing free play
Exist play→Replace.
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Place a stand under the engine to
raise the front wheel off the
ground. WARNING! Securely
support the vehicle so that
there is no danger of it falling
over.
2. Check:
• Steering stem
Grasp the bottom of the forks and
gently rock the fork assembly
back and forth.
Free play→Adjust steering head.
3. Check:
• Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action→Adjust steer-
ing ring nut. Stiffer "a" →Increase the high
compression damping force.
(Turn the adjuster "1" in.)
Softer "b" →Decrease the high
compression damping force.
(Turn the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position2 turns out
(from maximum
position)
Standard position:
About 1-1/8 turns out
* About 1-1/4 turns out
* For AUS, NZ and ZA
Standard tire pressure:
100 kPa (1.0 kgf/cm
2,
15 psi)
Spoke nipple wrench:
YM-01521/90980-01521
Spokes:
3 Nm (0.3 m•kg, 2.2
ft•lb)

5-26
VALVES AND VALVE SPRINGS
h. Press the valve through the valve
guide and onto the valve seat to
make a clear pattern.
i. Measure the valve seat width
again. If the valve seat width is out
of specification, reface and relap
the valve seat.
CHECKING THE VALVE SPRINGS
1. Measure:
• Valve spring free length "a"
Out of specification→Replace.
2. Measure:
• Compressed spring force "a"
Out of specification→Replace.
b. Installed length
3. Measure:
• Spring tilt "a"
Out of specification→Replace.CHECKING THE VALVE LIFTERS
1. Inspect:
• Valve lifter
Scratches/damage→Replace
both lifters and cylinder head.
INSTALLING THE VALVES
1. Apply:
• Molybdenum disulfide oil
Onto the valve stem and valve
stem seal.
2. Install:
• Valves "1"
• Valve spring seats "2"
• Valve stem seals "3"
• Valve springs "4"
• Valve spring retainers "5"
• Make sure that each valve is in-
stalled in its original place, also re-
ferring to the painted color as
follows.
Intake (middle) "a": blue
Intake (right/left) "b": gray
Exhaust "c": brown
• Install the valve springs with the
larger pitch "d" facing upward.
e. Smaller pitch
3. Install:
• Valve cotters
While compressing the valve spring
with a valve spring compressor "1" in-
stall the valve cotters.
4. To secure the valve cotters onto
the valve stem, lightly tap the
valve tip with a piece of wood.
Hitting the valve tip with excessive
force could damage the valve.
5. Install:
• Adjusting pad "1"
• Valve lifter "2"
• Apply the molybdenum disulfide oil
on the valve stem end.
• Apply the engine oil on the valve lift-
ers.
• Valve lifter must turn smoothly
when rotated with a finger.
• Be careful to reinstall valve lifters
and pads in their original place.
Free length (valve
spring):
Intake:
39.46 mm (1.55 in)
: 38.46 mm
(1.51 in)
Exhaust:
37.61 mm (1.48 in)
: 36.61 mm
(1.44 in)
Compressed spring
force:
Intake:
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)
Exhaust:
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)
Spring tilt limit:
Intake:
2.5°/1.7 mm (0.067 in)
Exhaust:
2.5°/1.6 mm (0.063 in)
Valve spring compres-
sor:
YM-4019/90890-04019

5-55
ENGINE REMOVAL
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE DRIVE
SPROCKET
1. Remove:
• Nut (drive sprocket) "1"
• Lock washer "2"
• Straighten the lock washer tab.
• Loosen the nut while applying the
rear brake.
2. Remove:
• Drive sprocket "1"
• Drive chain "2"
Remove the drive sprocket together
with the drive chain.
REMOVING THE ENGINE
1. Remove:
• Pivot shaft "1"
If the pivot shaft is pulled all the way
out, the swingarm will come loose. If
possible, insert a shaft of similar di-
ameter into the other side of the swin-
garm to support it.
2. Remove:
• Engine "1"
From right side.
Make sure that the couplers, hoses
and cables are disconnected.
INSTALLING THE ENGINE
1. Install:
• Engine "1"
Install the engine from right side.
• Pivot shaft "2"
• Engine mounting bolt (lower) "3"
• Lower engine bracket "4"
• Bolt (lower engine bracket) "5"
• Patch "6"
• Engine mounting bolt (front) "7"
• Upper engine bracket "8"
• Bolt (upper engine bracket) "9"
• Engine mounting bolt (upper) "10"
• Apply the molybdenum disulfide
grease on the pivot shaft.
• Install the patch with the claw "a"
facing outside the chassis.
INSTALLING THE BRAKE PEDAL
1. Install:
• Spring "1"
• Brake pedal "2"
• O-ring "3"
• Bolt (brake pedal) "4"
• Clip "5"
Apply the lithium soap base grease
on the bolt, O-rings and brake pedal
bracket.
INSTALLING THE DRIVE
SPROCKET
1. Install:
• Drive sprocket "1"
• Drive chain "2"
Install the drive sprocket together
with the drive chain.
2. Install:
• Lock washer "1"
Pivot shaft:
85 Nm (8.5 m•kg, 61
ft•lb)
Engine mounting bolt
(lower):
53Nm (5.3 m•kg, 38
ft•lb)
Bolt (lower engine brack-
et):
34 Nm (3.4 m•kg, 24
ft•lb)
Engine mounting bolt
(front):
53 Nm (5.3 m•kg, 38
ft•lb)
Bolt (upper engine brack-
et):
55 Nm (5.5 m•kg, 40
ft•lb)
Engine mounting bolt
(upper):
55 Nm (5.5 m•kg, 40
ft•lb)
Bolt (brake pedal):
26 Nm (2.6 m•kg, 19
ft•lb)