2012-2015 Yamaha WR450F Service & Repair Manual

2012-2015 OWNER’S SERVICE MANUAL WR450FB 1DX-28199-10 LIT-11626-25-58 q Read this manual carefully before operating this vehicle.

Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

EAS1DX3002 WR450FB OWNER’S SERVICE MANUAL ©2012 by Yamaha Motor Corporation, U.S.A. 1st Edition, January 2012 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-11626-25-58

EAS1DX3003 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama- ha'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. TIP 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. EWA1DX0001 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 INSPEC- TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE. EAS1DX3004 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. WARNING NOTICE TIP

EAS1DX3005 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 char- acteristics. • 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 preopera- tion 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. Car- bon 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, 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. • PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT. For safety, drain the gasoline from the fuel tank before transporting the vehicle.

EAS1DX3006 YAMAHA MOTOR CORPORATION, U.S.A. WR MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants to the original retail purchaser that the following components equipped on new Yamaha WR motorcycles purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in materiel and workmanship for the period of time stated herein, subject to certain stated limitations. WR components included under this warranty are the engine, frame, swingarm, and monoshock. It is understood that the balance of the WR components are not covered by any warranty, expressed or implied. The balance of the components equipped on the unit are sold on an 11 85 is" basis. This warranty applies to the original purchaser only and is not transferable. THE PERIOD OF WARRANTY for the above-listed Yamaha 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. I . Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER'S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the WR as specified in the appropriate Owne~s Service Manual, 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 deale~s place of business. EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation, U.S.A. also warrants to the ultimate purchaser and each subsequent purchaser of each 2006 and later model Yamaha motorcycle covered by this warranty that the vehicle is designed, built, and equipped so as to conform at the time of sale with all U.S. emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the period listed immediately below. Failures other than those resulting from defects in material or workmanship which arise solely as a result of owner abuse and/or lack of proper maintenance are not covered by this warranty. WARRANTY QUESTIONS AND ANSWERS All Off-Road Models Thirty (30) months from the original purchase date YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND RTNESS 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 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 0. 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. 0. 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 WR exact- ly as specified in the Owner's Service Manual? A. No. The warranty on a new motorcycle cannot be " vo ided" 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. a. 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.

EAS1DX3007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check 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 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, names of parts, notes in jobs, etc. • Jobs “7” requiring more information (such as special tools and technical data) are described se- quentially. 1 7 3 4 6 2 5

EAS1DX3008 SYMBOLS The following symbols are used in this manual for easier understanding. TIP The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium-soap-based grease Wear limit, clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent (LOCTITE®). Engine oil Replace the part with a new one. G M BF B T R . . LS M S LT E New

1 2 3 4 5 6 7 8 9 10 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUST- MENTS TUNING CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING

2012-2015 Yamaha WR450F Service & Repair Manual

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