2003-2005 Yamaha WR450F Service & Repair Manual

LIT-11626-17-49 WR450FS 5TJ-28199-11 OWNER’S SERVICE MANUAL

A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. YAMAHA LIT-CALIF-65-01

EC010000 WR450FS OWNER’S SERVICE MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st Edition, August 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-17-49

EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction 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. NOTE: As improvements are made on this model, some data in this manual may become out- dated. If you have any questions, please consult your Yamaha dealer. WARNING 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 MAINTE- NANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELI- ABILITY OF THIS MACHINE.

EC030002 YAMAHA MOTOR CORPORATION, U.S.A. YZ/WR MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby war· rants to the original retail purchaser that the fol- lowing components equipped on new Yamaha YZ or WR motorcycles purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein. subject to certain stated limitations. YZ or WR components included under this warranty are the engine, frame, swingarm, and monoshock. It is understood that the balance of the YZ or WR com· ponents are not covered by any warranty, expressed or implied. The balance of the compo· nents equipped on the unit are sold on an "as is" basis. This warranty applies to the original pur· chaser only and is not transferable. THE PERIOD OF WARRANTY for the above-listed Yamaha YZ or WR components as originally installed on the unit shall be thirty (30) days from the date of purchase. MODELS EXCLUDED FROM WARRANTY include those used for non-Yamaha-authorized renting, leasing, or other commercial purposes. DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will, free of charge, repair or replace, at Yamaha's option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used in warranty repairs will be warranted for the balance of the product's warranty period. All parts replaced under warranty become property of Yamaha Motor Corporation U.S.A. GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. b. Abnormal strain, neglect, or abuse. c. Accident or collision damage. d. Modification to original parts. e. Lack of proper maintenance. f. Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or rou- tine maintenance. THE CUSTOMER'S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the YZ or WR as specified in the appropriate Owner's Service Man- ual, and 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (10) days after discovery, and make the machine available at that time for inspection and repairs at such dealer's place of busi- ness. YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRAN· TIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE WARRANTY QUESTIONS AND ANSWERS LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIRC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. YAMAHA MOTOR CORPORATION, U.S.A. CUSTOMER SERVICE Post Office Box 6555 Cypress, California 90630 a. What costs are my responsibility during the warranty period? A. The customer's responsibility includes all costs of normal maintenance services, non-warranty repairs, accident and collision damage, and oil, oil filters, air filters, spark plugs, and brake shoes or pads. a. What are some examples of "abnormal" strain, neglect, or abuse? A. These terms are general and overlap each other in areas. Specific examples include: Run- ning the machine without oil; operating the machine with a broken or damaged part which causes another part to fail, damage or failure due to improper or, careless transportation and or tie down; and so on. If you have any specific questions on operation or maintenance, please contact your dealer for advice. If your machine requires warranty service, you must take it to any authorized Yamaha motorcycle dealer within the continental United States. Be sure to bring your warranty registration identification or other valid proof of the original date of purchase. If a question or problem arises regarding warranty, first contact the owner of the dealer-ship. Since all warranty matters are handled at the dealer level, this person is in the best position to help you. If you are still not satisfied and require additional assistance, please write: a. Does the warranty cover incidental costs such as towing or transportation due to a failure? A. No. The warranty is limited to repair of the machine itself. a. May I perform any or all of the recommended maintenance shown in the Owner's Service Manual instead of having the dealer do them? A. Yes, if you are a qualified mechanic and follow the procedures specified in the Owner's Service Manual. We do recommend, however, that items requiring special tools or equip- ment be done by a Yamaha motorcycle dealer. a. Will the warranty be void or canceled if I do not operate or maintain my new YZ or WR exactly as specified in the Owner's Service Manual? A. No. The warranty on a new motorcycle cannot be "voided" or "cancelled." However, if a particular failure is caused by operation or maintenance other than as shown in the Owner's Service Manual, that failure may not be covered under warranty. Q. What responsibility does my dealer have under this warranty? A. Each Yamaha motorcycle dealer is expected to: 1. Completely set up every new machine before sale. 2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date. In addition, each Yamaha motorcycle dealer is held responsible for his setup, service and warranty repair work. a. Does the warranty on the engine include the carburetor, air filter, air box, and exhaust pipe? A. No. The warranty covers only the engine components. YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT P.O. Box 6555 Cypress, California 90630 When contacting Yamaha Motor Corporation, U.S.A. don't forget to include any important information such as names, addresses, model, V.I.N. (frame number), dates, and receipts. CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related defect and recall. This list is compiled from the purchase registra- tions sent to Yamaha Motor Corporation, U.S.A. by the selling dealer at the time of your purchase. If you should move after you have purchased your new motorcycle, please advise us of your new address by sending a postcard listing your motorcycle model name, V.I.N. (frame number), dealer number (or deale's name) as it is shown on your warranty identification, your name and new mailing address. Mail to: YAMAHA MOTOR CORPORATION, U.S.A. WARRANTY DEPARTMENT P.O.Box 6555 Cypress, California 90630 This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date registration record in accordance with federal law.

IMPORTANT NOTICE 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 regula- tions before riding. 1. 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 character- istics. 2. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine. 3. ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with gog- gles 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. 4. 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. 5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refu- eling. 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. SAFETY INFORMATION

6. 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. 7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILA- TION. 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 color- less. Carbon monoxide is a dangerous gas which can cause unconscious- ness or can be lethal. 8. 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. 9. THE ENGINE, EXHAUST PIPE, MUF- FLER, AND OIL TANK 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. 10. PROPERLY SECURE THE MACHINE 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.

EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold. EC060000 NOTICE Some data in this manual may become out- dated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. EC070001 F.I.M. MACHINE WEIGHTS: 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.

EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: EC082000 FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; “General Information”, “Specifications”, “Regular inspection and adjustments”, “Engine”, “Chassis”, “Electrical” and “Tuning”. 2. The table of contents is at the beginning of the manual. Look over the general lay- out of the book before 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 description.

EC083000 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 mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., ● Bearings Pitting/damage → Replace. EC084002 HOW TO READ DESCRIPTIONS To help identify parts and clarify procedure steps, there are exploded diagrams 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 order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly 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 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unneces- sary removal job. 6. For jobs requiring more information, the step-by-step format supplements 6 are given in addition to the exploded diagram and job instruction chart.

2003-2005 Yamaha WR450F Service & Repair Manual

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