2004 YAMAHA WR 450F check oil

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-14
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-14 ~ 18
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-10
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10 ~ 11
Brakes Check the play of front brake and effect of front and rear brake. P.3-26 ~ 32
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-33 ~ 36
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-44 ~ 45
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-45 ~ 46
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-36 ~ 43
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks.—
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-33
Lubrication Check for smooth operation. Lubricate if necessary. P.3-47
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-19
Lead connectorsCheck that the AC magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 21

3 - 14
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
ENGINE OIL LEVEL INSPECTION
1. Stand the motorcycle on a level surface.
NOTE:
When checking the oil level make sure that
the motorcycle is upright.
Place the motorcycle on a suitable stand.
WARNING
Never remove the oil tank cap just after
high speed operation. The heated oil could
spurt out. causing danger. Wait until the oil
cools down to approximately 70 ˚C (158 ˚F).
2. Idle the engine more than 3 minutes
while keeping the motorcycle upright.
Then stop the engine and inspect the oil
level.
3. Remove:
Oil tank cap 1
1
4. Inspect:
Oil level
Oil level should be between maximum
a and minimum b marks.
Oil level low → Add oil to proper level.
NOTE:
When inspecting the oil level, do not screw the
oil level gauge into the oil tank.
Insert the gauge lightly.
a
b

3 - 17
INSP
ADJ
ENGINE OIL REPLACEMENT
6. If the oil filter is to be replaced during this
oil change, remove the following parts
and reinstall them.
7. Install:
Plain washer 1
Oil strainer (frame) 2
Engine oil hose 3
Bolt (engine oil hose) 4
Engine oil hose clamp 5
Engine skid plate
8. Install:
Gaskets
Oil filter drain bolt
Drain bolt (crankcase rear)
Drain bolt (crankcase left)
Drain bolt (frame)
9. Fill:
Crankcase Replacement steps:
Remove the oil filter cover 1 and oil filter
element 2.
Check the O-rings 3, if cracked or dam-
aged, replace them with a new one.
Install the oil filter element and oil filter
cover.
T R..
Oil filter cover:
10 Nm (1.0 m • kg, 7.2 ft • lb)
Oil quantity:
Periodic oil change:
1.0 L (0.88 Imp qt, 1.06 US qt)
With oil filter replacement:
1.1 L (0.97 Imp qt, 1.16 US qt)
Total amount:
1.2 L (1.06 Imp qt, 1.27 US qt)
New
T R..70 Nm (7.0 m · kg, 50 ft · lb)
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)

3 - 18
INSP
ADJ
PILOT SCREW ADJUSTMENT
10. Install:
Oil filler plug
11. Inspect:
Engine (for oil leaks)
Oil level
Refer to “ENGINE OIL LEVEL INSPEC-
TION”.
12. Check:
Oil pressure
PILOT SCREW ADJUSTMENT
1. Adjust:
Pilot screw 1
* Except for USAChecking steps:
Slightly loosen the oil gallery bolt 1.
Start the engine and keep it idling until oil
starts to seep from the oil gallery bolt. If no
oil comes out after one minute, turn the
engine off so it will not seize.
Check oil passages, oil filter and oil pump
for damage or leakage.
Start the engine after solving the prob-
lem(s) and recheck the oil pressure.
Tighten the oil gallery bolt to specification.
T R..
Oil gallery bolt:
10 Nm (1.0 m • kg, 7.2 ft • lb)
Adjusting steps:
NOTE:
To optimize the fuel flow at a smaller throttle
opening, each machine’s pilot screw has
been individually set at the factory. Before
adjusting the pilot screw, turn it in fully and
count the number of turns. Record this num-
ber as the factory-set number of turns out.
Turn in the pilot screw until it is lightly
seated.
Turn out the pilot screw by the factory-set
number of turns.
Pilot screw:
1-3/4 turns out (example)
*1-1/2 turns out (example)

3 - 19
INSP
ADJIDLE SPEED ADJUSTMENT/
VALVE CLEARANCE ADJUSTMENT
EC35M021
IDLE SPEED ADJUSTMENT
1. Start the engine and thoroughly warm it
up.
2. Adjust:
Idle speed
VALVE CLEARANCE ADJUSTMENT
NOTE:
The valve clearance should be adjusted
when the engine is cool to the touch.
The piston must be at Top Dead Center
(T.D.C.) on compression stroke to check or
adjust the valve clearance.
1. Remove:
Seat
Fuel tank
Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
2. Remove:
Carburetor
Refer to “CARBURETOR” section in
the CHAPTER 4.
Spark plug
Engine stay (upper)
Cylinder head cover
Refer to “CAMSHAFTS” section in the
CHAPTER 4. Adjustment steps:
Adjust the pilot screw.
Refer to “PILOT SCREW ADJUSTMENT”
section.
Turn the throttle stop screw 1 until the
specified engine idling speed.
NOTE:
Using a digital engine tachometer for idle
speed adjustment, detect the engine idling
speed by bringing the sensing element c of
the engine tachometer close to the ignition
coil 2.
To increase idle speed →
Turn the throttle stop screw 1 in a.
To decrease idle speed →
Turn the throttle stop screw 1 out b.
Engine idling speed:
1,700 ~ 1,900 r/min
c2

3 - 34
INSP
ADJ
DRIVE CHAIN INSPECTION
5. Check:
Drive chain stiffness a
Clean and oil the chain and hold as
illustrated.
Stiff → Replace the drive chain.
6. Install:
Joint 1
O-ring 2
Drive chain 3
NOTE:
When installing the drive chain, apply the lith-
ium soap base grease on the joint and O-rings.
7. Install:
Link plate 4
NOTE:
Press the link plate onto the joint using a
chain riveter 5.
Rivet the end of the joint using a chain riv-
eter.
After riveting the joint, make sure its move-
ment is smooth.
New
New
8. Lubricate:
Drive chain
Drive chain lubricant:
SAE 10W-30 motor oil or suit-
able chain lubricants

3 - 49
INSP
ADJ
IGNITION TIMING CHECK
IGNITION TIMING CHECK
1. Remove:
Timing plug 1
1
2. Attach:
Timing light
Inductive tachometer
To the ignition coil lead (orange lead
1).
Timing light:
YM-33277-A/90890-03141
1
3. Adjust:
Engine idling speed
Refer to “IDLE SPEED ADJUST-
MENT”.
4. Check:
Ignition timing
Visually check the stationary pointer a
is within the firing range b on the rotor.
Incorrect firing range → Check rotor
and pickup assembly.
5. Install:
Timing plug

4 - 26
ENGCAMSHAFTS
Decompression system
1. Check:
Decompression system
Checking steps:
Check that the decompressor cam 1
moves smoothly.
Check that the decompressor lever pin 2
projects from the camshaft.
Timing chain tensioner
1. Check:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver 1
and wind the tensioner rod up fully
clockwise.
When releasing the screwdriver by
pressing lightly with fingers, make sure
that the tensioner rod will come out
smoothly.
If not, replace the tensioner assembly.
ASSEMBLY AND INSTALLATION
1. Install:
Exhaust camshaft 1
Intake camshaft 2
Installation steps:
Turn the crankshaft counterclockwise until
the “I” mark a on the rotor is aligned with
the stationary pointer b on the crankcase
cover.
NOTE:
Apply the molybdenum disulfide oil on the
camshafts.
Apply the engine oil on the decompression
system.