2003 YAMAHA WR 450F lights

GEN
INFO

1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1
Clutch lever
2
Hot starter lever
3
“ENGINE STOP” button
4
Trip meter
5
Main switch
6
Lights switch
7
Start switch
8
Front brake lever
9
Throttle grip
0
Radiator cap
A
Fuel tank cap
B
Taillight
C
Kickstarter
D
Fuel tank
E
Headlight
F
Radiator
G
Coolant drain bolt
H
Rear brake pedal
I
Valve joint
J
Fuel cock
K
Cold starter knob
L
Air cleaner
M
Drive chain
N
Shift pedal
O
Oil dipstick
P
Front fork
NOTE:


The machine you have purchased may differ
slightly from those shown in the following.

Designs and specifications are subject to
change without notice.
B
CDE
F
G H
1234
5
6
7
8
9
0 A
IJ
K
L
M N
O P

1 - 10
GEN
INFO
CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
MAIN SWITCH
Functions of the respective switch positions
are as follows:
ON:
The engine can be started only at this position.
OFF:
All electrical circuits are switched off.
Main switch indicator light
The main switch 1 is equipped with an indica-
tor light 2 to avoid forgetting to turn it off. This
light functions as follows.
It lights up with the main switch “ON”.
It goes out when the engine increases its
speed after being started.
It lights up again when the engine is stopped.
NOTE:
If the indicator light will not light up with the
main switch “ON”, it shows a lack of the battery
voltage. Recharge the battery. If the engine is
kick started, turn off the light switch.
EC151000
“ENGINE STOP” BUTTON
The “ENGINE STOP” button 1 is located on
the left handlebar. Continue pushing the
“ENGINE STOP” button till the engine comes
to a stop.
START SWITCH
The start switch 1 is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.

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GEN
INFO
LIGHTS SWITCH
The lights switch 1 is located on the handle-
bar.
EC15F000
VALVE JOINT
This valve joint 1 prevents fuel from flowing
out and is installed to the fuel tank breather
hose.
CAUTION:
In this installation, make sure the arrow
faces the fuel tank and also downward.
SPARK PLUG WRENCH
This spark plug wrench 1 is used to remove
and install the spark plug.
1
1
NIPPLE WRENCH
This nipple wrench 1 is used to tighten the
spoke.
CONTROL FUNCTIONS

SPEC
2 - 15
MAINTENANCE SPECIFICATIONS
NOTE:
1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut
wrench, then loosen the ring nut one turn.
2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb). Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Handle crown and outer tube M8 × 1.25 4 23 2.3 17
Under bracket and outer tube M8 × 1.25 4 20 2.0 14
Handle crown and steering shaft M24 × 1.0 1 145 14.5 105
Handlebar holder (upper) M8 × 1.25 4 28 2.8 20
Steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and cap bolt M48 × 1.0 2 30 3.0 22
Front fork and base valve M30 × 1.0 2 55 5.5 40
Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21
Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7
Front fork and protector M6 × 1.0 6 10 1.0 7.2
Front fork and brake hose holder M6 × 1.0 2 10 1.0 7.2
Front fork and hose cover M8 × 1.25 1 16 1.6 11
Front fork and hose cover M6 × 1.0 1 7 0.7 5.1
Throttle cable cap M5 × 0.8 2 4 0.4 2.9
Clutch lever holder mounting M5 × 0.8 2 4 0.4 2.9
Hot starter lever holder mounting M5 × 0.8 2 4 0.4 2.9
Hot starter lever mounting M5 × 0.8 1 2 0.2 1.4
Lights switch M4 × 0.7 2 2 0.2 1.4
Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3
Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
Hose guide (front brake hose) M5 × 0.8 2 4 0.4 2.9
Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Front brake caliper and front fork M8 × 1.25 2 23 2.3 17
Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2
Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13
Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3
Front wheel axle and nut M16 × 1.5 1 105 10.5 75
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
Brake pedal mounting M8 × 1.25 1 26 2.6 19
Rear brake master cylinder and frame M6 × 1.0 2 11 1.1 8.0
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22

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SPEC

CABLE ROUTING DIAGRAM
EC240000
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 sen-
sor) lead
9
Neutral switch lead
0
Oil hose
A
Hose holder
B
Radiator hose 4
C
Cylinder head breather hose
D
AC magneto lead
E
Radiator hose 1
F
Oil tank breather hose
G
Lights switch lead
H
Brake hose
I
Hose guide
J
Carburetor breather hose
K
Overflow hose
LCoolant reservoir tank breather
hose
ÅInsert the fuel tank breather
hose into the hole in the steering
shaft cap.
ıFasten the diode of the wire har-
ness and rectifier/regulator lead
(at its protecting tube) to the
frame at the white tape for the
diode with a plastic locking tie
and cut off the tie end.ÇFasten the wire harness, recti-
fier/regulator lead, coolant res-
ervoir hose and hot starter cable
to the frame with a plastic lock-
ing tie and cut off the tie end.
ÎFasten the wire harness, recti-
fier/regulator lead and coolant
reservoir hose to the frame with
a plastic locking tie and cut off
the tie end.
‰Fasten the wire harness to the
frame at its white tape with a
plastic locking tie and cut off the
tie end.

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SPECCABLE ROUTING DIAGRAM
ÏFasten 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.
ÌMake sure that the TPS cou-
pler does not go out the chas-
sis.
ÓFasten the TPS lead to the
frame with a plastic band.
ÈFasten the neutral switch lead
and oil hose together with the
plastic locking ties and cut off
the tie ends.
ÔPass the cylinder head
breather hose through the hose
holder.Fasten the neutral switch lead
to the frame with a plastic band
ends outward.
ÒFasten the neutral switch lead
and AC magneto lead to the
frame with a plastic band.
˜Pass the cylinder head
breather hose on the outside of
the radiator hose 1 and on the
inside of the radiator pipe (radi-
ator hose 4).
ˆPass the oil tank breather hose
on the outside of the AC mag-
neto lead, neutral switch lead,
lights switch lead, wire harness
and cylinder head breather
hose.ØPass the wire harness on the
outside of the neutral switch
lead and AC magneto lead.
∏Fit the brake hose into the
guides on the protector.
ŒPass the wire harness through
the cable guide.
ÂFasten the AC magneto lead,
neutral switch lead and lights
switch lead to the cable guide
at their protecting tube with a
plastic locking tie and cut off
the tie end.
ÍPass the carburetor breather
hoses, overflow hose and cool-
ant reservoir tank breather
hose so that the hoses do not
contact the rear shock
absorber.

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SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Brake hose
3Clamp
4Lights switch lead
5Hot starter cable
6Clutch cable
7Hose guide
8Clutch switch lead
9“ENGINE STOP” button
lead
0Trip meter cable
AMain switch lead
BTrip meter
CMain switch
DLights switch
EStart switch leadÅFasten the start switch lead and
lights switch lead to the handlebar
with a plastic band.
ıFasten the “ENGINE STOP” but-
ton lead and clutch switch lead to
the handlebar with the plastic
bands.
ÇPass the brake hose through the
hose guide.
ÎPass the start switch lead in front
of the main switch lead.
‰Fasten the start switch lead to the
handlebar with a plastic band.
ÏPass the hot starter cable and
lights switch lead between the
handle crown and coupler
bracket.ÌPass the throttle cables and clutch
cable between the handle crown
and trip meter.

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CHAS
EC5B0000
HANDLEBAR
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Headlight
1 Hot starter cable 1 Disconnect at the lever side.
2 Hot starter lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1 Disconnect the clutch switch lead.
5“ENGINE STOP” button 1 Disconnect the “ENGINE STOP” button
lead.
6 Lights switch 1
7 Master cylinder 1 Refer to “REMOVAL POINTS”.
8 Start switch 1 Disconnect the start switch lead.
9 Throttle cable cap 1
10 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
11 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
12 Grip (right) 1 Refer to “REMOVAL POINTS”.
13 Tube guide 1
14 Cover (grip cap) 1
15 Grip (left) 1 Refer to “REMOVAL POINTS”.
16 Handlebar holder (upper) 2
17 Handlebar 1
1
HANDLEBAR