2004 YAMAHA WR 450F tow

1 - 11
GEN
INFO
CONTROL FUNCTIONS
EC152000
CLUTCH LEVER
The clutch lever 1 is located on the left han-
dlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disen-
gage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
EC153000
SHIFT PEDAL
The gear ratios of the constant-mesh 5 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
EC154000
KICKSTARTER
Rotate the kickstarter 1 away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kickstarter so the engine can be
started in any gear if the clutch is disengaged.
In normal practices, however, shift to neutral
before starting.
1
EC155001
THROTTLE GRIP
The throttle grip 1 is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.
EC156000
FRONT BRAKE LEVER
The front brake lever 1 is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.

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GEN
INFO
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com-
ponents.
1. Before washing the machine, block off
the end of the exhaust pipe to prevent
water from entering. A plastic bag
secured with a rubber band may be used
for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush.
Do not apply degreaser to the chain,
sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a
garden hose; use only enough pressure
to do the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a
soft towel or cloth.
6. Immediately after washing, remove
excess water from the chain with a paper
towel and lubricate the chain to prevent
rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.

GEN
INFO
NETTOYAGE ET RANGEMENT
REINIGUNG UND STILLEGUNG
LIMPIEZA Y ALMACENAMIENTO
8. Lack- und Chromflächen kön-
nen mit Autowachs poliert
werden. Kombinierte Reiniger
und Polituren sind zu vermei-
den, da sie oft Scheuermittel
enthalten, die den Lack auf
Tank und Verkleidungsteilen
beschädigen würden.
9. Nach der Wäsche den Motor an-
lassen und warmlaufen lassen.
STILLEGUNG
Vor einer mehr als zweimonatigen
Stillegung sollten einige Schutzvor-
kehrungen getroffen werden, um
Schäden zu verhindern. Das Fahr-
zeug zuerst gründlich reinigen und
dann folgendermaßen zur Stillegung
vorbereiten:
1. Kraftstofftank, Kraftstoffleitun-
gen und Vergaser-Schwim-
merkammer entleeren.
2. Die Zündkerze herausschrau-
ben, ungefähr einen Teelöffel
Motoröl in die Kerzenbohrung
geben und die Zündkerze wie-
der hineinschrauben. Bei ge-
drücktem Motorstoppschalter
den Kickstarter mehrmals
durchtreten, um das Öl in der
Zylinderlaufbuchse zu vertei-
len.
3. Die Antriebskette lösen,
gründlich reinigen und dann
schmieren. Die Kette wieder
montieren oder in einem am
Rahmen befestigten Plastik-
beutel aufbewahren.
4. Alle Seilzüge ölen.
5. Das Fahrzeug ganz aufbok-
ken, um beide Räder vom Bo-
den abzuheben.
6. Eine Plastiktüte über die
Schalldämpferöffnung stül-
pen, um Eindringen von
Feuchtigkeit zu verhindern.
7. Bei Lagerung in extrem feuch-
ter oder salzhaltiger Luft auf
alle Metalloberflächen einen
dünnen Ölfilm auftragen. Je-
doch niemals Gummiteile oder
den Sitzbankbezug einölen.
HINWEIS:
Anfallende Reparaturen vor der Still-
legung ausführen. 8. Un encaustique pour automobile
peut être appliqué sur toutes les
surfaces peintes et chromées. Evi-
ter les liquides de nettoyage à
encaustique, car ils contiennent
de l’abrasif.
9. Les opérations ci-dessus termi-
nées, lancer le moteur et le laisser
tourner pendant quelques minu-
tes.
RANGEMENT
Si l’on remise la machine pour 60 jours
ou plus, il faut prendre des mesures de
conservation pour éviter sa détérioration.
Après un nettoyage soigné, préparer la
machine de la manière suivante:
1. Vider le réservoir, les conduites
d’essence et la cuve du carbura-
teur.
2. Déposer la bougie, verser une
cuillère à soupe d’huile moteur
SAE 10W-30 dans le trou de bou-
gie, et la remettre en place.
Coupe-circuit à la position arrêt,
donner plusieurs coups de pédale
pour enduire le cylindre d’huile.
3. Déposer la chaîne, la nettoyer soi-
gneusement au dissolvant et
lubrifier. Remonter la chaîne ou
la ranger dans un sachet plastique
fermé fixé au cadre.
4. Lubrifier tous les câbles de com-
mande.
5. Mettre le cadre sur plots pour
soulever les roues du sol.
6. Fixer un sachet plastique sur la
sortie du pot d’échappement pour
éviter l’introduction d’humidité.
7. Si la machine est placée dans une
atmosphère humide ou marine,
enduire toutes les surfaces métal-
liques nues d’une fine couche
d’huile. Ne pas appliquer d’huile
sur les parties en caoutchouc ou
sur la selle.
N.B.:
Avant de ranger la machine, effectuer
toutes les réparations en souffrance.8. Puede aplicar cera de automotor a
todas las superficies pintadas o
cromadas. Evite la combinación
de limpiadores y ceras ya que
contienen sustancias abrasivas.
9. Después de completar el procedi-
miento, arranque el motor y
déjelo unos minutos en ralentí.
ALMACENAMIENTO
Si necesita guardar el vehículo durante
60 días o más, debe tomar algunas medi-
das preventivas para evitar que se dete-
riore. Después de limpiar a fondo el
vehículo, prepárelo para el almacena-
miento tal y como se indica a continua-
ción:
1. Drene el depósito de combustible,
las líneas de combustible y la
cubeta del flotador del carbura-
dor.
2. Extraiga la bujía, vierta una
cucharada de aceite de motor
SAE 10W-30 en el orificio de la
bujía y vuelva a colocar la bujía.
Con el interruptor de parada del
motor pulsado hacia adentro,
mueva el motor varias veces para
cubrir las paredes del cilindro con
aceite.
3. Extraiga la cadena de la caja de
cambios, límpiela a fondo con
disolvente y engrásela. Vuelva a
montar la cadena o guárdela en
una bolsa de plástico atada al bas-
tidor.
4. Engrase todos los cables de con-
trol.
5. Bloquee el bastidor para elevar
las ruedas del suelo.
6. Ate una bolsa de plástico alrede-
dor de la salida del tubo de escape
para evitar que penetre humedad.
7. Si va a guardar el vehículo en un
ambiente húmedo o salino, cubra
toda la superficie de metal
expuesta con una capa fina de
aceite. No aplique aceite a las pie-
zas de goma o a la cubierta del
asiento.
NOTA:
Realice cualquier reparación necesaria
antes de guardar el vehículo.
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3 - 5
INSP
ADJ
EC350000
ENGINE
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap 1, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:
Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Inspect:
Coolant level
Coolant level should be between the
maximum a and minimum b marks.
Coolant level is below the “LOW” level
line → Add soft water (tap water) up to
the proper level.
3. Start the engine and let it warm up for
several minutes.
4. Turn off the engine and check the coolant
level again.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant settles.
LOWFULLCOOLANT
a
b
COOLANT REPLACEMENT
WARNING
Do not remove the radiator cap when the
engine is hot.
ENGINE/COOLANT LEVEL INSPECTION/
COOLANT REPLACEMENT

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INSP
ADJ
CHASSIS/BRAKE SYSTEM AIR BLEEDING
EC360000
CHASSIS
EC361012
BRAKE SYSTEM AIR BLEEDING
WARNING
Bleed the brake system if:
The system has been disassembled.
A brake hose has been loosened or
removed.
The brake fluid is very low.
The brake operation is faulty.
A dangerous loss of braking performance
may occur if the brake system is not prop-
erly bled.
1. Remove:
Master cylinder cap
Diaphragm
Reservoir float (front brake)
Protector (rear brake)
2. Bleed:
Brake fluid
ÅFront
ıRear
Air bleeding steps:
a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic tube 2 tightly
to the caliper bleed screw 1.
d. Place the other end of the tube into a
container.
e. Slowly apply the brake lever or pedal
several times.
f. Pull the lever in or push down on the
pedal. Hold the lever or pedal in position.
g. Loosen the bleed screw and allow the
lever or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever
or pedal limit has been reached; then
release the lever or pedal.
T R..
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
i. Repeat steps (e) to (h) until of the air
bubbles have been removed from the
system.
Å
ı

4 - 4
ENG

EXHAUST PIPE AND SILENCER
INSPECTION
Exhaust pipe and silencer
1. Inspect:

Gasket
1

Damage
→
Replace.
1

ASSEMBLY AND INSTALLATION
Exhaust pipe and silencer
1. Install:

Gasket

Exhaust pipe
1


Nut (exhaust pipe)
2


Bolt (exhaust pipe)
3

NOTE:

First, temporarily tighten the nut (exhaust pipe),
then tighten the bolt (exhaust pipe) 20 Nm
(2.0 m • kg, 14 ft • lb). After that, retighten the
nut (exhaust pipe) 13 Nm (1.3 m • kg, 9.4 ft • lb)
and then the bolt (exhaust pipe) 24 Nm
(2.4 m • kg, 17 ft • lb).
3
1 2New
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..24 Nm (2.4 m · kg, 17 ft · lb)

2. Install:

Clamp
1


Gasket
2


Silencer
3


Washer
4

Bolt (silencer)
5

NOTE:


Install the gasket with its meshed area
a
toward the exhaust pipe side.

The gasket should be installed according to
the dimension shown.
2New 1 3
4
5
5
a
T R..16 Nm (1.6 m · kg, 11 ft · lb)
New
T R..35 Nm (3.5 m · kg, 25 ft · lb)
2.5~3.5 mm (0.10 ~ 0.14 in)

4 - 6
ENGRADIATOR
EC456000
HANDLING NOTE
WARNING
Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury.
When the engine has cooled, open the radi-
ator cap by the following procedure:
Place a thick rag, like a towel, over the radi-
ator cap, slowly rotate the cap counter-
clockwise to the detent. This procedure
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning coun-
terclockwise and remove it.
EC454000
INSPECTION
EC444100
Radiator
1. Inspect:
Radiator core 1
Obstruction → Blow out with com-
pressed air through rear of the radiator.
Bent fin → Repair/replace.
EC455000
ASSEMBLY AND INSTALLATION
Radiator
1. Install:
Pipe 1 1
Hose 1 2
Pipe 2 3
Hose 3 4
Hose 4 5
2. Install:
Hose 2 1
Radiator (left) 2
T R..10 Nm (1.0 m · kg, 7.2 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)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 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)

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ENGKICK AXLE AND SHIFT SHAFT
3. Install:
Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
4. Install:
Kick axle assembly 1
Plain washer 2
NOTE:
Apply the molybdenum disulfide grease on
the contacting surfaces of the kick axle stop-
per a and stopper plate 3.
Apply the engine oil on the kick axle.
Slide the kick axle assembly into the crank-
case and make sure the kick axle stopper fits
into the stopper plate.
5. Hook:
Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
Kick idle gear
1. Install:
Kick idle gear 1
Plain washer 2
Circlip 3
NOTE:
Install the kick idle gear with its depressed
side a toward you.
Apply the engine oil on the kick idle gear
inner circumference.
New