2005 YAMAHA WR 450F light

SPEC
2 - 3 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 305 mm (12.0 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
GENERAL SPECIFICATIONS

SPEC
2 - 17
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 15 1.5 11
Headlight body and headlight unit M6 × 1.0 2 7 0.7 5.1
Headlight mounting (left and right) M6 × 1.0 2 7 0.7 5.1
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 20 2.0 14 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
MAINTENANCE SPECIFICATIONS

SPEC
2 - 18
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 5TJ-80/YAMAHA (For USA)
5TJ-90/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 10/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 SH712AC/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 5TJ10/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) ----
MAINTENANCE SPECIFICATIONS

2 - 26
SPECCABLE ROUTING DIAGRAM
1Master cylinder
2Brake hose holder
3Brake hoseÈInstall the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the caliper.
ÉPass the brake hose into the
brake hose holders.
ÊIf the brake hose contacts the
spring (rear shock absorber),
correct its twist.
ËInstall the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion 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
0BatteryÈPosition the starter motor lead,
negative battery lead and wire
harness in the tank damper slit.
ÉFasten the wire harness to the
frame with a plastic locking tie
and cut off the tie end.
ÊFasten the coolant reservoir
tank breather hose and coolant
reservoir hose to the frame with
a plastic locking tie.
ËDo not allow the taillight lead to
slacken.
ÌPass the starter motor lead and
negative battery lead over the
carburetor.
ÍFasten the coolant reservoir
tank breather hose and coolant
reservoir hose to the frame with
a plastic band.ÎPass the coolant reservoir hose
on the outside of the coolant
reservoir tank breather hose.
7Ì4
Í
5
Ë
4
Ê
7
6
È3
2
1
4
É
4
Í4
Í
Î 0
968
213
Zero ~ 10 mm
(Zero ~ 0.39 in)

3 - 14
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
ENGINE OIL LEVEL INSPECTION
1. Stand the machine on a level surface.
NOTE:
When checking the oil level make sure that
the machine is upright.
Place the machine 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 machine 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
IDLE SPEED 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
EC35M021
IDLE SPEED ADJUSTMENT
1. Start the engine and thoroughly warm it up.
2. Adjust:
Idle speed Checking 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)
Adjustment steps:
Turn the throttle stop screw 1 until the
specified engine idling speed.
NOTE:
Using a digital engine tachometer for idle
speed adjustment, detect the engine idling
speed by bringing the sensing element c of
the engine tachometer close to the ignition
coil 2.
To increase idle speed
→
Turn the throttle stop screw
1 in
a.
To decrease idle speed
→
Turn the throttle stop screw
1 out
b.
Engine idling speed:
1,700 ~ 1,900 r/min
c2

3 - 24
INSP
ADJ
SPARK ARRESTER CLEANING (For USA)
WARNING
Be sure the exhaust pipe and silencer are
cool before cleaning the spark arrester.
Do not start the engine when cleaning the
exhaust system.
1. Remove:
Screw (silencer cap) 1
1
2. Remove:
Bolt (spark arrester) 1
1
3. Remove:
Tail pipe 1
Gasket (tail pipe) 2
Spark arrester 3
Pull the spark arrester out of the silencer.
Gasket (spark arrester) 4
4. Clean:
Spark arrester
Tap the spark arrester lightly, then use a
wire brush to remove any carbon depos-
its.
5. Install:
Gasket (spark arrester)
Spark arrester
Insert the spark arrester into the silencer
and align the bolt holes.
Gasket (tail pipe)
Bolt (spark arrester)
12
34
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
6. Install:
Silencer cap
NOTE:
First tighten the two screws a located horizon-
tally apart, and then tighten the others.aa
T R..5 Nm (0.5 m · kg, 3.6 ft · lb)
SPARK ARRESTER CLEANING (For USA)