2004 YAMAHA WR 450F light

SPEC

2 - 3
GENERAL SPECIFICATIONS
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI
Generator system AC magneto
Battery type YTZ7S
Battery voltage/capacity 12 V/6 AH
Specific gravity 1.310
Headlight type: Quartz bulb (halogen)
Bulb wattage
×
quantity:
Headlight 12 V 60/55 W
×
1
Taillight 12 V 21/5 W
×
1

SPEC
2 - 17
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race. Meter cable holder and protector M5 × 0.8 2 4 0.4 2.9
Headlight stay (lower) and under bracket M8 × 1.25 2 7 0.7 5.1
Headlight body and headlight unit M6 × 1.0 2 7 0.7 5.1
Headlight mounting (left and right) M6 × 1.0 2 10 1.0 7.2
Headlight mounting (lower) M6 × 1.0 1 7 0.7 5.1
Taillight mounting M6 × 1.0 3 4 0.4 2.9
Taillight lead clamp and rear fender M4 × 1.59 2 0.5 0.05 0.36
Coolant reservoir tank mounting M6 × 1.0 2 7 0.7 5.1
Sidestand bracket mounting M10 × 1.25 2 66 6.6 48
Drive chain stopper and sidestand bracket M6 × 1.0 1 7 0.7 5.1
Sidestand mounting M8 × 1.25 1 25 2.5 18 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb

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) ----

2 - 26
SPECCABLE ROUTING DIAGRAM
1Master cylinder
2Brake hose holder
3Brake hoseÅInstall the brake hose so that its
pipe portion directs as shown and
lightly touches the projection on
the caliper.
ıPass the brake hose into the
brake hose holders.
ÇIf the brake hose contacts the
spring (rear shock absorber), cor-
rect its twist.
ÎInstall the brake hose so that its
pipe portion directs as shown and
lightly touches the projection on
the master cylinder.

2 - 27
SPECCABLE ROUTING DIAGRAM
1Starter motor lead
2Negative battery lead
3Wire harness
4Clamp
5Taillight lead
6Coolant reservoir tank
breather hose
7Coolant reservoir hose
8Positive battery lead
9Starting circuit cut-off
relay
0BatteryÅPosition the starter motor lead,
negative battery lead and wire
harness in the tank damper slit.
ıFasten the wire harness to the
frame with a plastic locking tie and
cut off the tie end.
ÇDo not allow the taillight lead to
slacken.
ÎPass the starter motor lead and
negative battery lead over the car-
buretor.
‰Fasten the coolant reservoir tank
breather hose and coolant reser-
voir hose to the frame with a plas-
tic band.ÏPass the coolant reservoir hose
on the outside of the coolant res-
ervoir tank breather hose.

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 - 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 - 25
INSP
ADJ
SPARK ARRESTER CLEANING (For USA)
WARNING
Be sure the exhaust pipe and muffler are
cool before cleaning the spark arrester.
Do not start the engine when cleaning the
exhaust system.
1. Remove:
Bolt (spark arrester) 1 1
1
2. Remove:
Spark arrester 1
Pull the spark arrester out of the muf-
fler.
1
3. Clean:
Spark arrester
Tap the spark arrester lightly, then use
a wire brush to remove any carbon
deposits.
4. Install:
Spark arrester
Insert the spark arrester into the muffler
and align the bolt holes.
Bolt (spark arrester)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
SPARK ARRESTER CLEANING (For USA)