oil YAMAHA WR 450F 2011 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.
For Canada
The design and manufacture of this
Yamaha machine fully comply with
the emissions standards for clean air
applicable at the date of manufacture.
Yamaha has met these standards
without reducing the performance or
economy of operation of the machine.
To maintain these high standards, it
is important that you and your Yama-
ha dealer pay close attention to the
recommended maintenance sched-
ules and operating instructions con-
tained within this manual.
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.
IMPORTANT MANUAL
INFORMATION
Particularly important information is
distinguished in this manual by the
following notations.
This is the safety alert symbol. It is
used to alert you to potential per-
sonal injury hazards. Obey all safe-
ty messages that follow this
symbol to avoid possible injury or
death.
A WARNING indicat es a hazardous
situation which, if not avoided,
could result in death or serious in-
jury.
A NOTICE indicates special pre-
cautions that must be taken to
avoid damage to the vehicle or oth-
er property.
A TIP provides key information to
make procedures easier or clearer.
SAFETY INFORMATION
For Canada
This machine is designed for off-road
use only. 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.
Except for Canada
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 also be illegal.
Please check local regulations before
riding.
• THIS MACHINE IS TO BE OPER- ATED BY AN EXPERIENCED RID-
ER ONLY.
Do not attempt to operate this ma-
chine at maximum power until you
are totally familiar with its character-
istics.
• THIS MACHINE IS DESIGNED TO
BE RIDDEN BY THE OPERATOR
ONLY.
Do not carry passengers on this
machine. • ALWAYS WEAR PROTECTIVE
APPAREL.
When operating this machine, al-
ways wear an approved helmet with
goggles or a face shield. Also wear
heavy boots, gloves, and protective
clothing. Always wear proper fitting
clothing that will not be caught in
any of the moving parts or controls
of the machine.
• ALWAYS MAINTAIN YOUR MA- CHINE IN PROPER WORKING
ORDER.
For safety and reliability, the ma-
chine must be properly maintained.
Always perform the pre-operation
checks indicated in this manual.
Correcting a mechanical problem
before you ride may prevent an ac-
cident.
• GASOLINE IS HIGHLY FLAMMA- BLE.
Always turn off the engine while re-
fueling. 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.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gaso-
line, inhale excess gasoline vapors,
or allow any gasoline to get into
your eyes, contact a doctor immedi-
ately. If any gasoline spills onto
your skin or clothing, immediately
wash skin areas with soap and wa-
ter, and change your clothes.
• ONLY OPERATE THE MACHINE
IN AN AREA WITH ADEQUATE
VENTILATION.
Never start the engine or let it run
for any length of time in an enclosed
area. Exhaust fumes are poison-
ous. These fumes contain carbon
monoxide, which by itself is odor-
less and colorless. Carbon monox-
ide is a dangerous gas which can
cause unconsciousness or can be
lethal.
• PARK THE MACHINE CAREFUL- LY; TURN OFF THE ENGINE.
Always turn off the engine if you are
going to leave the machine. Do not
park the machine on a slope or soft
ground as it may fall over.
• THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL
BE VERY HOT AFTER THE EN-
GINE HAS BEEN RUN.
Be careful not to touch them or to
allow any clothing item to contact
them during inspection or repair.

HOW TO READ DESCRIPTIONS
To help identify parts and clarify pro-
cedure steps, there are exploded dia-
grams at the start of each removal
and disassembly section.
1. An easy-to-see exploded diagram "1" is provided for removal and
disassembly jobs. 2. Numbers "2" are given in the or-
der of the jobs in the exploded di-
agram. A number that is enclosed
by a circle indicates a disassem-
bly step.
3. An explanation of jobs and notes is presented in an easy-to-read
way by the use of symbol marks
"3". The meanings of the symbol
marks are given on the next page. 4. A job instruction chart "4" accom-
panies the exploded diagram,
providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more informa- tion, the step-by-step format sup-
plements "5" are given in addition
to the exploded diagram and job
instruction chart.
ILLUSTRATED SYMBO LS (Refer to
the illustration) Illustrated symbols "1" to "7" are used
to identify the specifications appear-
ing in the text.
1. With engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening
6. Specified value, Service limit
7. Resistance (
Ω), Voltage (V),
Electric current (A)
Illustrated symbols "8" to "13" in the
exploded diagrams indicate grade of
lubricant and location of lubrication
point.
8. Apply engine oil
9. Apply molybdenum disulfide oil
10. Apply brake fluid
11. Apply lightweight lithium-soap base grease
12. Apply molybdenum disulfide
grease
13. Apply silicone grease Illustrated symbols "14" to "15" in the
exploded diagrams indicate where to
apply a locking agent and where to in-
stall new parts.
14. Apply locking agent (LOC-
TITE
®)
15. Use new one
1
2 3
4 5

CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
LOCATION OF
IMPORTANT LABELS ..... 1-1
DESCRIPTION ................. 1-5
CONSUMER
INFORMATION................. 1-6
INCLUDED PARTS .......... 1-6
IMPORTANT
INFORMATION................. 1-6
CHECKING OF
CONNECTION .................. 1-7
SPECIAL TOOLS ............. 1-8
CONTROL
FUNCTIONS ................... 1-12
MULTI-FUNCTION
DISPLAY ........................ 1-13
STARTING AND
BREAK-IN ...................... 1-18
TORQUE-CHECK
POINTS........................... 1-20
CLEANING AND
STORAGE ...................... 1-21
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-12
LUBRICATION
DIAGRAMS .................... 2-19
CABLE ROUTING
DIAGRAM ....................... 2-21
CHAPTER 3
REGULAR INSPEC-
TION AND AD-JUSTMENTS
PERIODIC MAINTENANCE
CHART FOR THE EMISSION
CONTROL SYSTEM (For
Canada) ............................ 3-1
GENERAL MAINTENANCE
AND LUBRICATION CHART
(For Canada) .................... 3-2
MAINTENANCE
INTERVALS FOR
COMPETITION USE ......... 3-3
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-7
ENGINE ............................ 3-8
CHASSIS ........................ 3-19
ELECTRICAL ................. 3-29
CHAPTER 4 TUNING
ENGINE
(Except for Canada) ........ 4-1
CHASSIS .......................... 4-5
CHAPTER 5
ENGINE
RADIATOR ....................... 5-1
CARBURETOR................. 5-4
AIR INDICTOIN
SYSTEM ......................... 5-13
CAMSHAFTS.................. 5-15
CYLINDER HEAD........... 5-20
VALVES AND VALVE
SPRINGS ........................ 5-23
CYLINDER AND
PISTON ........................... 5-27
CLUTCH ......................... 5-30 OIL FILTER ELEMENT
AND WATER PUMP .......5-34
BALANCER ....................5-38
OIL PUMP .......................5-40
KICK SHAFT AND SHIFT
SHAFT ............................5-43
AC MAGNETO AND
STARTER CLUTCH........5-48
ENGINE REMOVAL........5-53
CRANKCASE AND
CRANKSHAFT ...............5-57
TRANSMISSION,
SHIFT CAM AND
SHIFT FORK ...................5-63
CHAPTER 6
CHASSIS
FRONT WHEEL AND REAR
WHEEL .............................6-1
FRONT BRAKE AND REAR
BRAKE..............................6-6
FRONT FORK .................6-16
HANDLEBAR..................6-23
STEERING ......................6-27
SWINGARM ....................6-31
REAR SHOCK
ABSORBER ....................6-36
CHAPTER 7
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........7-1
IGNITION SYSTEM...........7-3
ELECTRIC STARTING
SYSTEM............................7-5
CHARGING SYSTEM .....7-13
THROTTLE POSITION
SENSOR SYSTEM .........7-15
LIGHTING SYSTEM .......7-18
SIGNALING SYSTEM.....7-20

1-5
DESCRIPTION
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 tank 14. 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

1-7
CHECKING OF CONNECTION
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.
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.

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

1-18
STARTING AND BREAK-IN
STARTING AND BREAK-IN
FUEL
Always use the recommended fuel as
stated below. Also, be sure to use
new gasoline.
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to the engine inter-
nal parts such as valves, piston
rings, and exhaust system, etc.
If knocking or pinging occurs, use a
different brand of gasoline or higher
octane grade.
• For refueling, be sure to stop the
engine and use enough care not
to spill any fuel. Also be sure to
avoid refueling close to a fire.
• Refuel after the engine, exhaust pipe, etc. have cooled off.
Gasohol (For Canada)
There are two types of gasohol: gas-
ohol containing ethanol and that con-
taining methanol. Gasohol containing
ethanol can be used if the ethanol
content does not exceed 10%. Gaso-
hol containing methanol is not recom-
mended by Yamaha because it can
cause damage to the fuel system or
vehicle performance problems.
HANDLING NOTE
Never start or run the engine in a
closed area. The exhaust fumes
are poisonous; they can cause
loss of consciousness and death
in a very short time. Always oper-
ate the machine in a well-ventilated
area.
• The carburetor on this machine
has a built-in accelerator pump.
Therefore, when starting the en-
gine, do not operate the throttle
or the spark plug will foul. • Unlike a two-stroke engine, this
engine cannot be kick started
when the throttl e is open be-
cause the kickstarter may kick
back. Also, if the throttle is open
the air/fuel mixture may be too
lean for the engine to start.
• Before starting the machine, per- form the checks in the pre-opera-
tion check list.
AIR FILTER MAINTENANCE
According to "CLEANING THE AIR
FILTER ELEMENT" section in the
CHAPTER 3, apply the foam-air-filter
oil or its equivalent to the element.
(Excess oil in the element may ad-
versely affect engine starting.)
STARTING A COLD ENGINE
This model is equipped with an igni-
tion circuit cut-off system. The engine
can be started under the following
conditions.
• When the transmission is in neutral.
• When the clutch is disengaged with the transmission in any position.
However, it is recommended to shift
into neutral before starting the en-
gine.
1. Inspect the coolant level.
2. Turn the fuel cock to "ON".
3. Push on the main switch to "ON".
4. Shift the transmission into neutral.
5. Fully open the cold starter knob
"1".
6. Start the engine by pushing the start switch or by kicking the kick-
starter crank.
If the engine fails to start by pushing
the start switch, release the switch,
wait a few seconds, and then try
again. Each starting attempt should
be as short as possible to preserve
the battery. Do no t crank the engine
more than 10 seconds on any one at-
tempt. If the engine does not start
with the starter motor, try using the
kickstarter crank.
• If the starter mo tor will not turn
when pushing the start switch,
stop pushing it immediately and
kick start the engine in order to
avoid the load on the motor.
• Do not open the throttle while kicking the kickstarter crank.
Otherwise, the kickstarter crank
may kick back.
7. Return the cold starter knob to its
original position and run the en-
gine at 3,000–5,000 r/min for 1 or
2 minutes.
Since this model is equipped with an
accelerator pump, if the engine is
raced (the throttle opened and
closed), the air/fuel mixture will be too
rich and the engine may stall. Also
unlike a two-stroke engine, this model
can idle.
Do not warm up th e engine for ex-
tended periods of time.
STARTING A WARM ENGINE
Do not operate the cold starter knob
and throttle. Pull the hot starter lever
"1" and start the engine by pushing
the start switch or by kicking the kick-
starter crank forcefully with a firm
stroke. As soon as the engine starts,
Release the hot starter lever to close
the air passage.
Restarting an engine after a fall
Pull the hot starter lever and start the
engine. As soon as the engine starts,
Release the hot starter lever to close
the air passage.
Recommended fuel:
Premium unleaded
gasoline only with a re-
search octane number
of 95 or higher.

1-20
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
Frame construction Frame to rear frameCombined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder
Rear Tightening of wheel axle Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
Lubrication system Tighteni ng of oil hose clamp

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.

2-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name: WR450FA (USA, CDN, AUS, NZ)WR450F (EUROPE, ZA)
Model code number: 1HB1 (USA) 1HB2 (CDN)
1HB3 (EUROPE)
1HB4 (AUS, NZ, ZA)
Dimensions: USA, CDN, ZA EUROPE AUS, NZ
Overall length 2,175 mm (85.63 in)2,200 mm (86.61
in)2,185 mm (86.02
in)
Overall width 825 mm (32.48 in) ←←
Overall height 1,300 mm (51.18 in)1,305 mm (51.38
in)←
Seat height 980 mm (38.58 in) 990 mm (38.98 in) 985 mm (38.78 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) ←←
Weight: USACDN, EUROPE, AUS, NZ,
ZA
With oil and fuel 121 kg (267 lb) 122 kg (270 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 Recommended brand: YAMALUBE SAE 10W-30, SAE 10W-40, SAE 10W-50,
SAE 15W-40, SAE 20W-40 or SAE 20W-50
API service SG type or higher,
JASO standard MA
Oil capacity: Engine oilPeriodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt)
With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt)
Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes): 1.0 L (0.88 Imp qt, 1.06 US qt)
Air filter: Wet type element