2004 YAMAHA WR 450F oil

SPEC

2 - 11
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S
×
1.0 1 13 1.3 9.4
Camshaft cap M6
×
1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12
×
1.0 1 28 2.8 20
Cylinder head (stud bolt) M6
×
1.0 2 7 0.7 5.1
M8
×
1.25 1 15 1.5 11
(bolt) M10
×
1.25 4 Refer to NOTE.*
1

(nut) M6
×
1.0 2 10 1.0 7.2
Cylinder head cover M6
×
1.0 2 10 1.0 7.2
Cylinder M6
×
1.0 1 10 1.0 7.2
Timing chain tensioner M6
×
1.0 2 10 1.0 7.2
Tensioner cap bolt M6
×
1.0 1 7 0.7 5.1
Timing chain guide (rear) M6
×
1.0 2 10 1.0 7.2
Exhaust pipe (nut) M8
×
1.25 1 13 1.3 9.4
(bolt) M8
×
1.25 1 24 2.4 17
Silencer M8
×
1.25 2 35 3.5 25
Silencer clamp M8
×
1.25 1 16 1.6 11
Exhaust pipe protector M6
×
1.0 3 10 1.0 7.2
Spark arrester (for USA) M6
×
1.0 3 10 1.0 7.2
Silencer end pipe (for USA) M6
×
1.0 1 10 1.0 7.2
Carburetor joint clamp (cylinder head side) M5
×
0.8 1 3 0.3 2.2
Carburetor joint clamp (carburetor side) M4
×
0.7 1 3 0.3 2.2
Air filter case M6
×
1.0 2 8 0.8 5.8
Air filter joint clamp M6
×
1.0 1 3 0.3 2.2
Air filter joint and air filter case M5
×
0.8 1 4 0.4 2.9
Throttle cable (pull) M6
×
1.0 1 4 0.4 2.9
Throttle cable (return) M12
×
1.0 1 11 1.1 8.0
Throttle cable cover M5
×
0.8 2 4 0.4 2.9
Hot starter plunger M12
×
1.0 1 2 0.2 1.4
Radiator panel (upper) M6
×
1.0 2 10 1.0 7.2
Radiator M6
×
1.0 6 10 1.0 7.2
Radiator hose clamp M6
×
1.0 8 2 0.2 1.4
Radiator pipe 1, 2 M10
×
1.0 2 10 1.0 7.2
Impeller M8
×
1.25 1 14 1.4 10
Water pump housing cover M6
×
1.0 3 10 1.0 7.2
Coolant drain bolt M6
×
1.0 1 10 1.0 7.2
Oil pump cover M4
×
0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 10 1.0 7.2
Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2
Oil filter cover M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 M10 × 1.25 1 20 2.0 14
M8 × 1.25 2 18 1.8 13
Oil delivery pipe 2 M6 × 1.0 1 10 1.0 7.2
Oil hose M6 × 1.0 2 8 0.8 5.8

SPEC
2 - 12
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.
NOTE:
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence,
remove and retighten the cylinder head bolts to 20 Nm (2.0 m · kg, 14 ft · lb) in the proper tightening
sequence, and then tighten the cylinder head bolts further to reach the specified angle 180˚ in the
proper tightening sequence.Oil check bolt M6 × 1.0 1 10 1.0 7.2
Oil hose clamp–2 2 0.2 1.4
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase cover (right) M6 × 1.0 10 10 1.0 7.2
Crankcase cover (left) M6 × 1.0 9 10 1.0 7.2
Idle gear cover (starter motor) M6 × 1.0 2 10 1.0 7.2
Crankcase M6 × 1.0 12 12 1.2 8.7
Clutch cable holder M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (crankcase rear) M10 × 1.25 1 20 2.0 14
(crankcase left) M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (frame) M8 × 1.25 1 23 2.3 17
Oil strainer (frame) M14 × 1.5 1 70 7.0 50
Crankcase bearing stopper M6 × 1.0 15 10 1.0 7.2
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Stopper plate M6 × 1.0 2 12 1.2 8.7
Kickstarter M8 × 1.25 1 33 3.3 24
Screw (kickstarter) M6 × 1.0 1 7 0.7 5.1
Starter clutch M6 × 1.0 6 16 1.6 11
Primary drive gear M20 × 1.0 1 85 8.5 61
Clutch boss M20 × 1.0 1 75 7.5 54
Push lever M6 × 1.0 1 10 1.0 7.2
Clutch spring M6 × 1.0 6 8 0.8 5.8
Balancer driven gear M14 × 1.0 1 50 5.0 36
Balancer weight plate M6 × 1.0 3 10 1.0 7.2
Drive sprocket M20 × 1.0 1 75 7.5 54
Drive sprocket cover M6 × 1.0 2 8 0.8 5.8
Shift pedal M6 × 1.0 1 12 1.2 8.7
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
EC212201
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN EUROPE AUS, NZ, ZA
Front fork travel 300 mm (11.8 in)←←
Fork spring free length 460 mm (18.1 in)←←
Spring rate, STD K = 4.51 N/mm
(0.46 kg/mm,
25.8 lb/in)K = 4.12 N/mm
(0.42 kg/mm,
23.5 lb/in)K = 4.31 N/mm
(0.44 kg/mm,
24.6 lb/in)
Optional spring/spacer Yes←←
Oil capacity 578 cm
3
(20.3 Imp oz,
19.5 US oz) 573 cm3
(20.2 Imp oz,
19.4 US oz) ←
Oil level 125 mm (4.92 in) 130 mm (5.12 in)←

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)80 ~ 150 mm
(3.15 ~ 5.91 in)←←
Oil grade Suspension oil
“01”←←
Inner tube outer diameter 46 mm (1.81 in)←←
Front fork top endZero mm (Zero in)←←
Rear suspension: USA, CDN EUROPE AUS, NZ, ZA
Shock absorber travel 132 mm (5.20 in)←←
Spring free length260 mm (10.24 in)←←
Fitting length 245 mm (9.65 in)247 mm (9.72 in)←
240.5 ~ 258.5 mm
(9.47 ~ 10.18 in)←←
Spring rate, STD K = 52.0 N/mm
(5.30 kg/mm,
296.8 lb/in)K = 48.0 N/mm
(4.90 kg/mm,
274.4 lb/in)K = 54.0 N/mm
(5.50 kg/mm,
308.0 lb/in)
Optional spring Yes←←
Enclosed gas pressure
1,000 kPa
(10 kg/cm2, 142 psi)
←←
Swingarm:
Swingarm free play limit
End ---- 1.0 mm
(0.04 in)

SPEC
2 - 18
MAINTENANCE SPECIFICATIONS
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
C.D.I.:
Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)
(White – Red)----
CDI unit-model/manufacturer 5TJ50/YAMAHA (For USA)
5TJ60/YAMAHA
(Except for USA)----
----
Ignition coil:
Model/manufacturer 5TA-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.08 ~ 0.10 Ω at 20 ˚C (68 ˚F) ----
Secondary winding resistance 4.6 ~ 6.8 kΩ at 20 ˚C (68 ˚F) ----
Charging system:
System type AC magneto ----
Model (stator)/manufacturer 5TJ-01/YAMAHA ----
Normal output 14 V/120 W at 5,000 r/min ----
Charging coil resistance (color) 0.288 ~ 0.432 Ω at 20 ˚C (68 ˚F)
(White – Ground)----
Lighting coil resistance (color) 0.224 ~ 0.336 Ω at 20 ˚C (68 ˚F)
(Yellow – Ground)----
Rectifier/regulator:
Regulator type Semiconductor short circuit ----
Model/manufacture SH712AA/SHINDENGEN ----
Regulated voltage (AC) 13.0 ~ 14.0 V ----
Regulated voltage (DC) 14.1 ~ 14.9 V ----
Rectifier capacity (AC) 12 A ----
Rectifier capacity (DC) 8 A ----
Electric starting system:
Type Constant mesh ----
Starter motor:
Model/manufacturer 5TJ01/YAMAHA ----
Operation voltage 12 V ----
Output 0.48 kW ----
Armature coil resistance 0.0117 ~ 0.0143 Ω at 20 ˚C
(68 ˚F)----
Brush overall length 7 mm (0.28 in) 3.5 mm
(0.14 in)
Brash quantity 2 pcs. ----
Spring force 3.92 ~ 5.88 N
(400 ~ 600 g, 14.1 ~ 21.2 oz)----
Commutator diameter 17.6 mm (0.69 in) 16.6 mm
(0.65 in)
Mica undercut (depth) 1.5 mm (0.06 in) ----

SPEC
2 - 19
MAINTENANCE SPECIFICATIONS
NOTE:
Tighten the rotor nut to 65 Nm (6.5 m · kg, 47 ft · lb), loosen and retighten the rotor nut to 65 Nm
(6.5 m · kg, 47 ft · lb). Starter relay:
Model/manufacturer 2768090-A/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 ˚C (68 ˚F) ----
Starting circuit cut-off relay:
Model/manufacturer ACM33221 M06/MATSUSHITA ----
Coil winding resistance 75.69 ~ 92.51 Ω at 20 ˚C (68 ˚F) ----
Fuse (amperage × quantity):
Main fuse 10 A × 1 ----
Reserve fuse 10 A × 1 ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M5 × 0.8 2 7 0.7 5.1
Holder (AC magneto lead) M5 × 0.8 2 7 0.7 5.1
Rotor M12 × 1.25 1 Refer to NOTE.
Neutral switch M5 × 0.8 2 4 0.4 2.9
Starter motor M6 × 1.0 2 10 1.0 7.2
Starter relay terminal M6 × 1.0 2 4 0.4 2.9 Item Standard Limit

2 - 4
CARACTERISTIQUES D’ENTRETIEN
SPEC

CARACTERISTIQUES D’ENTRETIEN
MOTEUR
Article Standard Limite
Culasse:
Limite de déformation ---- 0,05 mm
(0,002 in)
Cylindre:
Alésage 95,00 à 95,01 mm
(3,7402 à 3,7406 in)----
Limite d’ovalisation ---- 0,05 mm
(0,002 in)
Arbre à cames:
Méthode d’entraînement Transmission par chaîne (gauche) ----
Diamètre intérieur de chapeau 22,000 à 22,021 mm
(0,8661 à 0,8670 in)----
Diamètre extérieur d’arbre à cames 21,967 à 21,980 mm
(0,8648 à 0,8654 in)----
Jeu entre arbre à cames et chapeau 0,020 à 0,054 mm
(0,0008 à 0,0021 in)0,08 mm
(0,003 in)
Dimensions de came
Admission“A”31,200 à 31,300 mm
(1,2283 à 1,2323 in)31,100 mm
(1,2244 in)
“B”22,550 à 22,650 mm
(0,8878 à 0,8917 in)22,450 mm
(0,8839 in)
Echappement“A”30,950 à 31,050 mm
(1,2185 à 1,2224 in)30,850 mm
(1,2146 in)
“B”22,494 à 22,594 mm
(0,8856 à 0,8895 in)22,394 mm
(0,8817 in)
Limite de voile d’arbre à cames ---- 0,03 mm
(0,0012 in)
A
B

2 - 14
CARACTERISTIQUES D’ENTRETIENSPEC
Roue:
Type de roue avant Roue à rayons ----
Type de roue arrière Roue à rayons ----
Taille/matériau de jante avant 21 × 1,60/aluminum ----
Taille/matériau de jante arrière 18 × 2,15/aluminum ----
Limite de voile de jante:
Radial ---- 2,0 mm
(0,08 in)
Latéral ---- 2,0 mm
(0,08 in)
Chaîne de transmission:
Type/fabricant DID520VM/DAIDO ----
Nombre de maillons 113 maillons + attache ----
Flèche de la chaîne 40 à 50 mm (1,6 à 2,0 in) ----
Longueur de chaîne (10 maillons) ----150,1 mm
(5,91 in)
Frein à disque avant:
Diamètre extérieur × épaisseur 250 × 3,0 mm (9,84 × 0,12 in) 250 × 2,5 mm
(9,84 × 0,10 in)
Epaisseur de plaquette 4,4 mm (0,17 in) 1,0 mm
(0,04 in)
Diamètre intérieur de maître-cylindre 11,0 mm (0,433 in) ----
Diamètre intérieur de cylindre d’étrier 27,0 mm (1,063 in) × 2 ----
Type de liquide de frein DOT n˚4 ----
Frein à disque arrière:
Diamètre extérieur × épaisseur 245 × 4,0 mm (9,65 × 0,16 in) 245 × 3,5 mm
(9,65 × 0,14 in)
Limite de flèche ----0,15 mm
(0,006 in)
Epaisseur de plaquette 6,4 mm (0,25 in) 1,0 mm
(0,04 in)
Diamètre intérieur de maître-cylindre 11,0 mm (0,433 in) ----
Diamètre intérieur de cylindre d’étrier 25,4 mm (1,000 in) × 1 ----
Type de liquide de frein DOT n˚4 ----
Levier de frein et pédale de frein:
Position du levier de frein 95 mm (3,74 in) ----
Hauteur de la pédale de frein
(hauteur en dessous le haut du repose-pied)5 mm (0,20 in) ----
Jeu de levier d’embrayage (au pivot du levier) 8 à 13 mm (0,31 à 0,51 in) ----
Jeu à la poignée d’accélération 3 à 5 mm (0,12 à 0,20 in) ---- Article Standard Limite

2 - 21
SPEC

LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1
Oil delivery pipe
2
Intake camshaft
3
Exhaust camshaft
4
Oil cleaner element
5
Oil pump
6
Main axle
7
Drive axle
7
6
543 2
14
5
A - A
D - D
G
G
D
D A
A