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  5. Supplementary Owner's Service Manual

Yamaha WR450F Supplementary Owner's Service Manual

Summary of WR450F

  • Page 1

    Wr450f(s) 2-trac supplementary owner’s service manual 5tj-f8199-e0

  • Page 2

    Wr450f(s) 2-trac supplementary owner’s service manual © 2004 by yamaha motor italia s.P.A. First edition, march 2004 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor italia s.P.A. Is expressly prohibited. Printed in italy.

  • Page 3: Contents

    1 contents hydrostatic transmission .......................................................................................... 2 when driving .............................................................................................................. 2 function .......................................

  • Page 4: Hydrostatic Transmission

    2 hydrostatic transmission when driving driving a two wheel driven motorcycle is different from driving a conventional motorcycle. The front wheel drive system, during certain conditions, affects the feeling of the handlebar. In sand, mud and snow the traction is greatly improved. However in conditi...

  • Page 5

    3 adjustments the pulling force, at a given circumstance, can be varied by changing the rear wheel sprocket up or down one tooth. If we increase the no by one tooth the pump rotates faster in relation to the hydraulic motor, thereby increasing the pressure in the system and increasing the pulling fo...

  • Page 6: Gen

    4 gen info special tools special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape ...

  • Page 7: Gen

    5 tool no. 90890-xxxxx (0727-03) soft jaws use this tool for piston shafts 14-16 mm. Tool name/how to use illustration 90890-xxxxx (04957-01) steering damper holder use this tool for holding the steering damper unit with or without link arm. 90890-xxxxx (04954-01) puller use this tool for demounting...

  • Page 8: Spec

    General specifications 6 spec specifications general specifications item standard model name: wr450f ’04 – 2-trac (europe) model code number: 5tj6 (europe) dimensions: overall length 2,171 mm (85.5 in) overall width 827 mm (32.6 in) overall height 1,303 mm (51.3 in) seat height 998 mm (39.3 in) whee...

  • Page 9: Spec

    Spec maintenance specifications 7 maintenance specifications chassis item standard limit front suspension: shock absorber travel 300 mm ••• fork spring free length 467 mm 460 mm installed length 463 mm (4 mm preload) ••• collar length – ••• spring rate (k1) 4.5 n/mm (left leg), 4.1 n/mm (right leg) ...

  • Page 10: Spec

    Spec maintenance specifications 8 tightening torques tightening part to be tightened thread torque remarks size n · m m · kg carburetor drain plug screw m6 x 0.75 2.5 0.25 engine guards (3, 4) and frame m8 x 1.25 23 2.3 frame and rear frame (upper) m8 x 1.25 32 3.2 frame and rear frame (under) m8 x ...

  • Page 11: Spec

    Spec cable routing diagram 9 cable routing diagram 1 fuel tank breather hose 2 clamp 3 diode 4 wire harness 5 hot starter cable 6 negative battery lead 7 starter motor lead 8 tps (throttle position sensor) lead 9 neutral switch lead 0 oil hose q hose holder w radiator hose 4 e cylinder head breather...

  • Page 12: Spec

    Spec cable routing diagram 10 ƒ fasten the wire harness, tps lead (in the wire harness), starter motor lead and negative battery lead to the frame with a plastic locking tie and cut off the tie end. © make sure that the tps coupler does not go out the chassis. ˙ fasten the tps lead to the frame with...

  • Page 13: Spec

    Spec cable routing diagram 11 1 drive chain housing (transmission assy) 2 pump (transmission assy) 3 hose (pump/reservoir) 4 reservoir (transmission assy) 5 hose (motor/pump) 6 bracket (reservoir) 7 clamp 8 motor (transmission assy).

  • Page 14: Spec

    Spec cable routing diagram 12 1 hot starter cable 2 clutch cable 3 throttle cable (return) 4 throttle cable (pull) 5 ignition coil 6 negative battery lead 7 starter motor lead 8 coolant reservoir tank breather hose 9 rectifier/regulator 0 cable holder q coolant reservoir hose w rectifier/regulator l...

  • Page 15: Spec

    Spec cable routing diagram 13 ∂ pass the carburetor breather hose (throttle cable cover) through the hose holder. ´ fasten the coolant reservoir tank breather hose and carbure- tor breather hoses together with a plastic locking tie. ƒ fasten the grommet of the clutch cable with the cable hold- er. ©...

  • Page 16: Spec

    Spec cable routing diagram 14 1 master cylinder 2 brake hose holder 3 brake hose å install the brake hose so that its pipe portion directs as shown and lightly touches the projec- tion on the caliper. ∫ pass the brake hose into the brake hose holders. ç if the brake hose contacts the spring (rear sh...

  • Page 17: Spec

    Spec cable routing diagram 15 1 starter motor lead 2 negative battery lead 3 wire harness 4 clamp 5 taillight lead 6 coolant reservoir tank breather hose 7 coolant reservoir hose 8 positive battery lead 9 starting circuit cut-off relay 0 battery å position the starter motor lead, negative battery le...

  • Page 18: Spec

    Spec cable routing diagram 16 1 throttle cable 2 clamp 3 brake hose 4 hot starter cable 5 clutch cable 6 hose guide 7 clutch switch lead 8 "engine stop" button lead 9 trip meter cable 0 main switch lead q steering damper cover w main switch e start switch lead r clamp (steering damper cover) å faste...

  • Page 19: Insp

    Insp adj maintenance intervals 17 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 mai...

  • Page 20: Insp

    18 insp adj steering damper adjustment steering damper adjustment the steering damper is a hydraulic damper that counteracts wobble, alleviates shock against the front wheel and prevents head shake/cast by the motorcycle, which gives safer riding. The damper is fitted on the upper fork crown, in the...

  • Page 21: Insp

    Insp adj steering damper adjustment 19 damping sweep controls damping sweep controls 5 are located on each side off the damper body. Damping is in position 2, (12 o´clock), when delivered from yamaha. This setting is fitted for enduro, motocross and off-road riding. Warning always ensure that valve ...

  • Page 22: Insp

    20 insp adj steering damper adjustment change the fluid regularly. In new dampers after 10 hours riding and then every 20 hours riding. Use only recommended fluid that is tested and ap- proved by yamaha. We cannot guarantee fully ac- ceptable operation using other fluids. Note: regular maintenance a...

  • Page 23: Insp

    Insp adj 21 front fork rebound damping force adjustment front fork rebound damping force adjustment the rebound adjuster is located at the top of the fork leg. 1. Adjust: • rebound damping force by turning the adjuster. Stiffer → increase the rebound damp- ing force. (turn the adjuster in.) softer →...

  • Page 24: Insp

    22 insp adj front fork compression damping force adjustment front fork compression damping force adjustment the compression adjuster is located at the bottom of the fork leg. 1. Adjust: • compression damping force by turning the adjuster. Stiffer → increase the compression damp- ing force. (turn the...

  • Page 25: Insp

    Insp adj 23 rear shock absorber spring preload adjustment rear shock absorber spring preload adjustment 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: • rear frame 3. Loosen: • locknut 1 4. Adjust: • spring preload by turning the adjuster 2 . Stiffer → increase ...

  • Page 26: Insp

    24 insp adj rear shock absorber rebound damping force adjustment rear shock absorber rebound damping force adjustment 1. Adjust: • rebound damping force by turning the adjuster 1 . Stiffer a → increase the rebound damp- ing force. Softer b → decrease the rebound damp- ing force. Extent of adjustment...

  • Page 27: Insp

    Insp adj 25 rear shock absorber low compression damping force adjustment rear shock absorber low compression damping force adjustment 1. Adjust: • low compression damping force by turning the adjuster 1 . Stiffer a → increase the low compres- sion damping force. (turn the adjuster 1 in.) softer b → ...

  • Page 28: Insp

    26 insp adj rear shock absorber high compression damping force adjustment rear shock absorber high compression damping force adjustment 1. Adjust: • high compression damping force by turning the adjuster 1 . Stiffer a → increase the high compres- sion damping force. (turn the adjuster 1 in.) softer ...