2004 YAMAHA WR 450F coolant level

1 - 15
GEN
INFO
STARTING AND BREAK-IN
STARTING AND BREAK-IN
WARNING
Never start or run the engine in a closed
area. The exhaust fumes are poisonous;
they can cause loss of consciousness and
death in a very short time. Always operate
the machine in a well-ventilated area.
CAUTION:
The carburetor on this machine has a
built-in accelerator pump. Therefore,
when starting the engine, do not operate
the throttle or the spark plug will foul.
Unlike a two-stroke engine, this engine
cannot be kick started when the throttle is
open because the kickstarter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the
engine to start.
Before starting the machine, perform the
checks in the pre-operation check list.
AIR FILTER MAINTENANCE
According to “AIR FILTER CLEANING” section
in the CHAPTER 3, apply the foam-air-filter oil
or its equivalent to the element. (Excess oil in
the element may adversely affect engine start-
ing.)
STARTING A COLD ENGINE
NOTE:
This model is equipped with an ignition circuit
cut-off system. The engine can be started
under the following conditions.
When the transmission is in neutral.
When the clutch is disengaged with the
transmission in any position. However, it is
recommended to shift into neutral before
starting the engine.
1. Inspect the coolant level.
2. Turn the fuel cock to “ON”.
3. Push the main switch to “ON”.
4. Shift the transmission into neutral.
5. Fully open the cold starter knob 1.
6. Start the engine by pushing the start
switch or by kicking the kickstarter.

3 - 2
INSP
ADJ

MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
Inspect
●
Inspect wear
ROTOR NUT
Retighten
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●

MUFFLER
Inspect and retighten
Clean
Replace
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●
* Whichever comes first
*SPARK ARRESTER
Clean
(Every
six
months)
●
CRANK
Inspect and clean
●

●

CARBURETOR
Inspect, adjust and clean
●

●

SPARK PLUG
Inspect and clean
Replace
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●

DRIVE CHAIN
Lubricate, slack, alignment
Replace
●

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Use chain lube
Chain slack: 40 ~ 50 mm
(1.57 ~ 1.97 in)
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant
Inspect hoses
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Every two years
OUTSIDE NUTS AND BOLTS
Retighten
●

●
Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1.
AIR FILTER
Clean and lubricate
Replace
●

●

●
Use foam air-filter oil or
equivalent oil
OIL FILTER
Replace
●

●

OIL STRAINER (frame)
Clean
●

FRAME
Clean and inspect
●

●

FUEL TANK, COCK
Clean and inspect
●

●

BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid
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Every one year ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)
As re-
quiredRemarks
3

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 - 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

3 - 7
INSP
ADJ
COOLANT REPLACEMENT
9. Fill:
Radiator
Engine
To specified level.
CAUTION:
Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
Do not use water containing impurities or oil.
Recommended coolant:
High quality ethylene glycol
anti-freeze containing
anti-corrosion for
aluminum engine
Coolant 1 and water
(soft water) 2 mixing ratio:
50%/50%
Coolant capacity:
1.25 L (1.10 Imp qt, 1.32 US qt)
Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.
When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
10. Install:
Radiator cap
11. Fill:
Coolant reservoir tank
Midway a between maximum and min-
imum marks on the tank.
LOWFULLCOOLANTa

3 - 8
INSP
ADJRADIATOR CAP INSPECTION/
RADIATOR CAP OPENING PRESSURE INSPECTION
12. Install:
Coolant reservoir cap
13. Start the engine and let it warm up for
several minutes.
14. Turn off the engine and inspect the cool-
ant level.
Refer to “COOLANT LEVEL INSPEC-
TION” section.
NOTE:
Before checking the coolant level wait a few
minutes until the coolant settles.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
Seal (radiator cap) 1
Valve and valve seat 2
Crack/damage → Replace.
Exist fur deposits 3 → Clean or
replace.
EC356001
RADIATOR CAP OPENING PRESSURE
INSPECTION
1. Attach:
Radiator cap tester 1 and adapter 2
NOTE:
Apply water on the radiator cap seal.
3Radiator cap
2. Apply the specified pressure.
Radiator cap tester:
YU-24460-01/90890-01325
Adapter:
YU-33984/90890-01352
Radiator cap opening pressure:
110 kPa (1.1 kg/cm2, 15.6 psi)

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INSP
ADJ
COOLING SYSTEM INSPECTION
3. Inspect:
Pressure
Impossible to maintain the specified
pressure for 10 seconds → Replace.
EC357002
COOLING SYSTEM INSPECTION
1. Inspect:
Coolant level
2. Attach:
Radiator cap tester 1 and adapter 2
3. Apply the specified pressure.
NOTE:
Do not apply pressure more than specified
pressure.
Radiator should be filled fully.
4. Inspect:
Pressure
Impossible to maintain the specified
pressure for 10 seconds → Repair.
Radiator
Radiator hose joint
Coolant leakage → Repair or replace.
Radiator hose
Swelling → Replace.
Radiator cap tester:
YU-24460-01/90890-01325
Adapter:
YU-33984/90890-01352
Standard pressure:
180 kPa (1.8 kg/cm2, 25.6 psi)

4 - 57
ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
REMOVAL POINTS
EC4G3110
Impeller shaft
1. Remove:
Impeller 1
Plain washer 2
Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats a with spanners, etc. and remove the
impeller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discolora-
tion of coolant, or milky transmission oil.
1. Remove:
Bearing 1
Oil seal 2
INSPECTION
EC444200
Impeller shaft
1. Inspect:
Impeller shaft 1
Bend/wear/damage → Replace.
Fur deposits → Clean.