2004 YAMAHA WR 450F fuel

3 - 58
INSP
ADJ
ADJUSTING THE HEADLIGHT BEAMS
5. Install:
Headlight bulb
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free form oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
6. Attach:
Headlight bulb holder
7. Install:
Headlight bulb holder cover
8. Install:
Headlight
Refer to “SEAT, FUEL TANK AND
SIDE COVERS” section in the CHAP-
TER 4.
New
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
Headlight beam (vertically)
Adjusting steps:
Turn the adjusting screw 1 in direction a
or b.
Direction a Headlight beam is raised.
Direction b Headlight beam is lowered.

4 - 1
ENG

EC400000
ENGINE
EC4R0000
SEAT, FUEL TANK AND SIDE COVERS
Extent of removal:
1
Seat removal
2
Fuel tank removal
3
Side covers removal
4
Headlight removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
SEAT, FUEL TANK AND SIDE
COVERS REMOVAL
Turn the fuel cock to “OFF”.
Disconnect the fuel hose.
1 Seat 1
2 Air scoop (left and right) 2
3 Fitting band 1 Remove on fuel tank side.
4 Bolt (fuel tank) 2
5 Fuel tank 1
6 Side cover (left) 1
Refer to “REMOVAL POINTS”.
7 Side cover (right) 1
8 Headlight coupler 1
9 Headlight 1
13
2
3
4

SEAT, FUEL TANK AND SIDE COVERS

4 - 2
ENG

REMOVAL POINTS
Side cover
1. Remove:

Bolt (side cover)

Side cover (left)
1

Side cover (right)
2
NOTE:

Draw the side cover downward to remove it
because its claws
a
are inserted in the air fil-
ter case.
SEAT, FUEL TANK AND SIDE COVERS

4 - 3
ENG

EXHAUST PIPE AND SILENCER
EC4S0000
EXHAUST PIPE AND SILENCER
Å
For USA
ı
Except for USA
Extent of removal:
1
Silencer removal
2
Exhaust pipe removal
Extent of removal Order Part name Q’ty Remarks
EXHAUST PIPE AND
SILENCER REMOVAL
Preparation for removal Side cover (right) Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Bolt (clamp) 1 Only loosening.
2 Bolt [silencer (front)] 1
3 Bolt [silencer (rear)] 1
4 Silencer 1
5 Clamp 1
6 Nut (exhaust pipe) 1
7 Bolt (exhaust pipe) 1
8 Exhaust pipe 1
9Gasket
2
2
1
2

4 - 5
ENG

RADIATOR
EC450001
RADIATOR
Extent of removal:
1
Radiator removal
2
Coolant reservoir removal
Extent of removal Order Part name Q’ty Remarks
RADIATOR REMOVAL
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Seat, fuel tank and side cover Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
1 Engine guard 1
2 Panel 2
3 Clamp 8
4 Radiator (right) 1
5 Hose 2 1
6 Hose 3 1
7 Hose 4 1
8 Pipe 2/O-ring 1/1
9 Radiator breather hose 1
10 Radiator (left) 1
11 Hose 1 1
12 Pipe 1/O-ring 1/1
13 Coolant reservoir hose 1
14 Coolant reservoir tank 1
1
2

4 - 8
ENGCARBURETOR
CARBURETOR
7 4
108
9
T R..2 Nm (0.2 m •
kg, 1.4 ft • Ib)
2
3
75
5
T R..4 Nm (0.4 m •
kg, 2.9 ft • Ib)
T R..3 Nm (0.3 m • kg, 2.2 ft • Ib)
6
T R..3 Nm (0.3 m • kg, 2.2 ft • Ib)
1
T R..4 Nm (0.4 m •
kg, 2.9 ft • Ib)
T R..11 Nm (1.1 m •
kg, 8.0 ft • Ib)
Extent of removal:1 Carburetor removal
Extent of removal Order Part name Q’ty Remarks
CARBURETOR REMOVAL
Preparation for removal Fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
1 Clamp 1
2 Band 1
3 TPS coupler 1
4 Throttle cable cover 1
5 Throttle cable 2
6 Clamp (air cleaner joint) 1 Loosen the screw (air cleaner joint).
7 Clamp (carburetor joint) 2 Loosen the screws (carburetor joint).
8 Hot starter plunger 1
9 Carburetor 1
10Carburetor joint
1
1

4 - 11
ENGCARBURETOR
EC466020
HANDLING NOTE
CAUTION:
Do not loosen the screws {TPS (throttle
position sensor)} 1 except when changing
the TPS (throttle position sensor) due to
failure because it will cause a drop in
engine performance.
1
REMOVAL POINTS
Pilot screw
1. Remove:
Pilot screw 1
NOTE:
To optimize the fuel flow at a small throttle
opening, each machine’s pilot screw has been
individually set at the factory. Before removing
the pilot screw, turn it in fully and count the
number of turns. Record this number as the
factory-set number of turns out.
INSPECTION
Carburetor
1. Inspect:
Carburetor body
Contamination → Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with com-
pressed air.
Never use a wire.
2. Inspect:
Main jet 1
Pilot jet 2
Needle jet 3
Starter jet 4
Pilot air jet 5
Leak jet 6
Damage → Replace.
Contamination → Clean.
NOTE:
Use a petroleum based solvent for cleaning.
Blow out all passages and jets with com-
pressed air.
Never use a wire.

4 - 21
ENGCAMSHAFTS
CAMSHAFTS
CYLINDER HEAD COVER
Extent of removal:1 Cylinder head cover removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD COVER
REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
1 Spark plug 1
2 Engine upper bracket (right) 1
3 Engine upper bracket (left) 1
4 Cylinder head breather hose 1
5 Oil tank breather hose 1
6 Bolt (cylinder head cover) 2
7 Cylinder head cover 1
8 Gasket 1
9 Timing chain guide (upper) 1
1