q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
WR450F
WR450FG
2GC-28199-70
Q
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
Q
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit
être remis avec le véhicule en cas de vente de ce dernier.
Read this manual carefully before operating this vehicle.Read this manual carefully before operating this vehicle.
Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha's vast experience in the production of pacesetting racing machines. It represents the highest
grade of craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you
have any questions about this manual or your machine, please contact your Yamaha dealer.
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 Yamaha dealer pay close attention to the recommended maintenance
schedules and operating instructions contained within this manual.
Yamaha continually seeks advancements 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.
EWA
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS 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 CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EAS2GC1004
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 personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
EAS2GC1005
SAFETY INFORMATION
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 OPERATED BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.
• 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, always 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 MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. 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 gasoline, inhale excess gasoline vapors, or allow any gasoline to get
into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, 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
poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; 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 AND MUFFLER WILL BE VERY HOT AFTER THE ENGINE HAS
BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
For safety, drain the gasoline from the fuel tank before transporting the vehicle.
EAS2GC1006
1
7
3
4
6
2
5
HOW TO USE THIS MANUAL
In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment
procedures are laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section
title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a removal or a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, the
names of parts, the notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequentially.
EAS2GC1007
TIP
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
SYMBOLS
The following symbols are used in this manual for easier understanding.
The following symbols are not relevant to every vehicle.
SYMBOLDEFINITIONSYMBOLDEFINITION
Serviceable with engine mountedGear oil
Filling fluidMolybdenum disulfide oil
LubricantBrake fluid
Special toolWheel bearing grease
Tightening torqueLithium-soap-based grease
Wear limit, clearanceMolybdenum disulfide grease
Engine speedSilicone grease
Electrical dataLocking agent (LOCTITE®)
Engine oilReplace the part with a new one.
TABLE OF CONTENS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
TUNING
CHASSIS
1
2
3
4
5
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
6
7
8
9
10
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS............................................................1-1
Please read the following important labels carefully before operating this vehicle.
CAN
1-1
LOCATION OF IMPORTANT LABELS
EUR
1-2
AUS, NZL, ZAF
LOCATION OF IMPORTANT LABELS
1-3
EAS2GC1009
TIP
321
8
10
91112 13
76
54
15142120 19 1817
16
DESCRIPTION
DESCRIPTION
1. Clutch lever12. Headlight
2. Multi-function display13. Radiator
3. Front brake lever14. Coolant drain bolt
4. Throttle grip15. Rear brake pedal
5. Start switch16. Air filter
6. Radiator cap17. Drive chain
7. Fuel tank cap18. Shift pedal
8. Engine stop switch19. Oil level check window
9. Taillight20. Starter knob/idle screw
10. Fuel tank21. Front fork
11. Kickstarter lever
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have purchased.
1-4
EAS2GC1010
1
1
1
1
IDENTIFICATION
There are two significant reasons for knowing
the serial number of your vehicle:
1. When ordering parts, you can give the num-
ber to your Yamaha dealer for positive identification of the model you own.
2. If your vehicle is stolen, the authorities will
need the number to search for and identify
your vehicle.
EAS2GC1011
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is
stamped into the right side of the frame.
IDENTIFICATION
A: For Canada
B: For USA and Canada
EAS2GC1012
ENGINE SERIAL NUMBER
The engine serial number “1” is stamped into
the elevated part of the right-side of the engine.
EAS2GC1013
VEHICLE EMISSION CONTROL INFORMATION LABEL
The Vehicle Emission Control Information label
“1” is affixed at the location in the illustration.
This label shows specifications related to exhaust emissions as required by federal law,
state law and Environment Canada.
1-5
INCLUDED PARTS
NOTICE
1
1
A
a
1
A
1
1
EAS2GC1014
INCLUDED PARTS
EAS2GC1015
SPARK PLUG WRENCH
The spark plug wrench “1” is used to remove or
install the spark plug.
EAS2GC1016
NIPPLE WRENCH
The nipple wrench “1” is used to tighten the
spoke.
EAS2GC1018
FUEL HOSE JOINT COVER
The fuel hose joint covers “1” are used to prevent mud, dust, and other foreign materials
from entering the inside when the fuel hose is
disconnected.
EAS2GC1019
COUPLER FOR CONNECTING OPTIONAL
PART
The coupler “1” is used for connecting the optional Power Tuner and so on.
ECA
When no optional parts, etc. are connected,
connect the connection terminal to the original coupler.
Before disconnecting the coupler, thoroughly wipe off any mud or water stuck to it.
EAS2GC1017
HANDLEBAR PROTECTOR
Install the handlebar protector “1” so that the
notch “a” face backward.
Part namePart number
GYTR Power Tuner
33D-H59C0-V2
(For USA)
YZ Power Tuner
33D-859C0-11
(Except for USA)
The Power Tuner is an optional part.
1-6
EAS20180
WARNING
IMPORTANT INFORMATION
EAS2GC1020
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the entry of them into the inside during the jobs.
• Before cleaning with high-pressure water of
washers, cover the following parts.
Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Hole under the water pump housing
IMPORTANT INFORMATION
4. During disassembly, clean each of the parts,
and store them in trays for each section.
5. Flammable. Keep servicing areas away
from any source of fire.
6. During servicing, take special care not to receive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore,
rinse it out with water in good time.
EWA
Coolant is potentially harmful and should
be handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
2. Use proper special tools and equipment.
See “SPECIAL TOOLS”.
3. During disassembly, check and measure the
required parts, and make a record of them
so that you may refer to the record when installing them. Moreover, arrange gears, cylinders, pistons, and other parts for each
section so as not to confuse or lose them.
EAS2GC1021
REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
used for repair of the vehicle, including periodic
replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar appearances or because the quality may be
changed by aging.
1-7
EAS2GC1022
NOTICE
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets and O-rings. All gasket surfaces, oil
seal lips, and O-rings must be cleaned so
that there may be no dust on them.
2. During assembly, always apply proper oil to
bearings and proper grease to oil seal lips
before installation.
1. Oil
2. Lip
3. Spring
4. Grease
EAS2GC1023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace lock washers/plates “1”
and cotter pins with new ones. After the bolt or
nut has been tightened to specification, firmly
bend the lock tabs along a flat of the bolt or nut.
IMPORTANT INFORMATION
EAS2GC1025
CIRCLIPS
When assembling parts, always use new circlips. During installation of a circlip, make sure
that the edge “2” of the circlip “1” is positioned
opposite to the force “3” that the circlip receives. Install the circlip with its end aligned
with the center of the spline, without opening
the circlip more than necessary.
EAS2GC1024
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” with their
manufacturer’s marks or size symbols facing
outward. During installation of an oil seal, make
sure that its main lip faces the oil chamber (the
target to be sealed). Before installation, always
apply a light coat of grease to the oil seal lip.
ECA
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
1-8
EAS2GC1026
NOTICE
NOTICE
TIP
NOTICE
NOTICE
NOTICE
BASIC SERVICE INFORMATION
EAS2GC1027
ELECTRICAL SYSTEM
Electrical parts handling
ECA
Never disconnect a battery lead while the
engine is running; otherwise, the electrical
components could be damaged.
BASIC SERVICE INFORMATION
ECA
Be sure to connect the battery leads to the
correct battery terminals. Reversing the
battery lead connections could damage the
electrical components.
ECA
When disconnecting the battery leads from
the battery, be sure to disconnect the negative battery lead first, then the positive battery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be generated, which is extremely dangerous.
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust using hot water.
ECA
When connecting the battery leads to the
battery, be sure to connect the positive battery lead first, then the negative battery
lead. If the negative battery lead is connected first and a tool or similar item contacts
the vehicle while the positive battery lead is
being connected, a spark could be generated, which is extremely dangerous.
ECA
Make sure that the multi-function display
goes off after pushing and holding the engine stop switch before disconnecting or
connecting any electrical components.
1-9
BASIC SERVICE INFORMATION
NOTICE
NOTICE
TIP
TIP
NOTICE
NOTICE
a
ECA
Handle electrical components with special
care, and do not subject them to strong
shocks.
ECA
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
Checking the electrical system
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
ECA
Never insert the tester probes into the coupler terminal slots. Always insert the probes
from the opposite end “a” of the coupler,
taking care not to loosen or damage the
leads.
Push and hold the engine stop switch to turn off
the multi-function display when resetting the
ECU (Electronic Control Unit). Disconnect the
starter motor lead of the starter relay, and then
push the starter switch. Be sure to wait for five
seconds or longer before pushing the start
switch after the multi-function display goes off.
ECA
For waterproof couplers, never insert the
tester probes directly into the coupler.
When performing any checks using a waterproof coupler, use the specified test harness or a suitable commercially available
test harness.
1-10
Checking the connections
NOTICE
NOTICE
TIP
1
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECA
• When disconnecting a coupler, release the
coupler lock, hold both sections of the
coupler, and then disconnect the coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of coupler lock before disconnecting the coupler.
BASIC SERVICE INFORMATION
2. Check:
• Lead
• Coupler
• Connector
Moisture Dry with compressed air.
Rust/stains Connect and disconnect several times.
3. Check:
• All connections
Loose connection Connect properly.
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are installed securely.
ECA
When disconnecting a connector, do not
pull the leads. Hold both sections of the
connector, and then disconnect the connector.
1-11
4. Connect:
TIP
TIP
• Lead
• Coupler
• Connector
• When connecting a coupler or connector,
make sure that both terminals are connected
securely.
• Make sure all connections are tight.
BASIC SERVICE INFORMATION
5. Check:
• No continuity
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-12
SPECIAL TOOLS
TIP
EAS2GC1028
SPECIAL TOOLS
The following special tools are required for accurate and complete adjustment and assembly. Using
the correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and tool number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
• For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use tool number starting with “90890-”.
Tool name/Part numberHow to useIllustration
Dial gauge & stand set
90890-01252
Dial gauge set
YU-03097-B
This tool is used to check
parts for runout or bend.
Crankshaft installer pot
90890-01274
Installing pot
YU-90058