2006 YAMAHA WR 450F oil

2 - 24
SPECCABLE ROUTING DIAGRAM
ÍFasten the wire harness, starter
motor lead and negative battery
lead to the frame with a plastic
locking tie and cut off the tie
end.
ÎMake sure that the TPS coupler
does not go out the chassis.
ÏFasten the TPS lead to the
frame with a plastic band.
ÐFasten the neutral switch lead
and oil hose together with the
plastic locking ties and cut off
the tie ends.
ÑFasten the neutral switch lead
to the frame with a plastic band
ends outward.ÒFasten the neutral switch lead
and AC magneto lead to the
frame with a plastic band ends
outward.
ÓPass the oil tank breather hose
on the outside of the AC mag-
neto lead, neutral switch lead,
wire harness, rectifier/regulator
lead and cylinder head breather
hose.
ÔPass the wire harness on the
outside of the neutral switch
lead and AC magneto lead.
ÕPass the wire harness through
the cable guide.
ÖFasten the rectifier/regulator
lead to the cable guide with a
plastic locking tie and cut off the
tie end.×Fasten the AC magneto lead
and neutral switch lead to the
cable guide at their protecting
tube with a plastic locking tie.
ØPass the carburetor breather
hoses, overflow hose and cool-
ant reservoir tank breather
hose so that the hoses do not
contact the rear shock
absorber.
ÙUsing a plastic locking tie, fas-
ten the CDI unit lead on the
right of the frame and then cut
off the tie end.
2
Ù
B
BA
B-B
A
A
0Ò2
Ñ2 B ÓC Ô D
EFÕÖ2
×2F
1
È
2
É
3
2
Ê
452
Ë
2
Ì2
Í
6
7
Î
2
Ï
8
9
0
A 2
ÐØ GG
HI

2 - 25
SPECCABLE ROUTING DIAGRAM
1Hot starter cable
2Clutch cable
3Throttle cable (return)
4Throttle cable (pull)
5Ignition coil
6Negative battery lead
7Starter motor lead
8Coolant reservoir tank breather
hose
9Cable holder
0Coolant reservoir hose
AClamp
BCDI unit lead
CCDI unit
DCDI unit band
ECDI unit stay (frame)
FCable bracketÈPass the throttle cables, clutch
cable and hot starter cable
through the cable guides.
ÉPass the throttle cables, clutch
cable and hot starter cable
between the radiator and frame,
then over the middle radiator
mounting boss.
ÊPass the throttle cables and
clutch cable on the outside of
the ignition coil.
ËPass the carburetor breather
hose (throttle cable cover)
through the hose holder.
ÌFasten the coolant reservoir
tank breather hose and carbure-
tor breather hoses together with
a plastic locking tie.ÍFasten the grommet of the clutch
cable with the cable holder.
ÎFasten the CDI unit lead to the
frame with a plastic locking tie
ends at the lower of the frame
and cut off the tie end.
ÏInsert the CDI unit band over the
CDI unit stay (frame) as far as
possible.
ÐFasten the starter motor lead
and negative battery lead to the
cable bracket in its slot with a
plastic locking tie and cut off the
tie end.
A
A
D
ÏE A
Ð
B
B
C
F
Í90
ÎABCD
1
2
43
È
É
Ê
5
6 7 8 Ë Ì

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
ENGINE OIL
Replace
VALVES
The engine must be cold.
Check the valve seats
and valve stems for wear. Check the valve clearances
Inspect
Replace
VALVE SPRINGS
Check the free length and
the tilt. Inspect
Replace
VALVE LIFTERS
Check for scratches and
wear. Inspect
Replace
CAMSHAFTS Inspect the camshaft sur-
face.
Inspect the decompres-
sion system Inspect
Replace
CAMSHAFT SPROCKETS
Check for wear on the
teeth and for damage. Inspect
Replace
PISTON
Inspect crack
Inspect carbon deposits
and eliminate them. Inspect
Clean
Replace
PISTON RING
Check ring end gap Inspect
Replace
PISTON PIN
Inspect
Replace
CYLINDER HEAD Inspect carbon deposits
and eliminate them.
Change gasket Inspect and clean
CYLINDER
Inspect and clean
Inspect score marks
Inspect wear
Replace
CLUTCH
Inspect housing, friction
plate, clutch plate and
spring Inspect and adjust
Replace
TRANSMISSION
Inspect
Replace bearing
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
ROTOR NUT
Retighten
MUFFLER
Inspect and retighten
Clean
Replace * Whichever comes first
*SPARK ARRESTER
(Every six
months)
Clean
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
AIR INDUCTION SYSTEM
Inspect and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN
Use chain lube
Chain slack: 48 ~ 58 mm
(1.9 ~ 2.3 in) Lubricate, slack, alignment
Replace
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1. Retighten
AIR FILTER
Use foam air-filter oil or
equivalent oil Clean and lubricate
Replace
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 Every one yearItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks


3

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
* marked: For USA
FRONT FORKS
Inspect and adjust
Replace oil Suspension oil “S1”
Replace oil seal
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube Lithium base grease
PROTECTOR GUIDE
Replace
REAR SHOCK ABSORBER
(After
rain ride)
Inspect and adjust
Lube
Molybdenum disulfide
grease
Retighten
DRIVE CHAIN GUARD AND ROLL-
ERS
Inspect
DRIVE CHAIN STOPPER
Inspect
SWINGARM
Molybdenum disulfide
grease
Inspect, lube and retighten
RELAY ARM, CONNECTING ROD
Molybdenum disulfide
grease
Inspect, lube and retighten
SIDESTAND
Lubricate Lithium base grease
STEERING HEAD
Inspect free play and retighten
Clean and lube Lithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate Lithium base grease
THROTTLE, CONTROL CABLE
Yamaha cable lube or
SAE 10W-30 motor oil Check routing and connection
Lubricate
HOT STARTER, CLUTCH LEVER
Inspect free play
BATTERY
Check terminal for looseness and
corrosionItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks

INSP
ADJ
*: USA
FOURCHES
Contrôler et régler
Remplacer l’huile Huile de fourche “S1”
Remplacer la bague d’étanchéité
BAGUE D’ETANCHEITE ET JOINT
ANTIPOUSSIERE DE FOURCHE
Nettoyer et lubrifier Graisse à base de lithium
GUIDE DE PROTECTION
Remplacer
AMORTISSEUR ARRIERE
(Après utili-
sation par
temps de
pluie)
Contrôler et régler
Lubrifier
Graisse au bisulfure de
molybdène
Resserrer
CARTER ET GALETS DE CHAINE DE
TRANSMISSION
Contrôler
BUTEE DE CHAINE DE TRANSMIS-
SION
Contrôler
BRAS OSCILLANT
Graisse au bisulfure de
molybdène
Contrôler, lubrifier et resserrer
BRAS RELAIS, BIELLE
Graisse au bisulfure de
molybdène
Contrôler, lubrifier et resserrer
BEQUILLE LATERALE
Lubrifier Graisse à base de lithium
TETE DE FOURCHE
Contrôler le jeu et resserrer
Nettoyer et lubrifier Graisse à base de lithium
Remplacer le roulement
PNEUS, ROUES
Contrôler la pression de gonflage, le
voile de roue, l’usure des pneus et la ten-
sion des rayons
Resserrer le boulon du pignon
Contrôler les roulements
Remplacer les roulements
Lubrifier Graisse à base de lithium
ACCELERATEUR, CABLE DE COM-
MANDE
Lubrifiant pour câbles
Yamaha ou huile moteur
SAE 10W-30 Contrôler le cheminement et le raccorde-
ment
Lubrifier
LEVIER DE DEMARRAGE A CHAUD,
LEVIER D’EMBRAYAGE
Contrôler le jeu
BATTERIE
Contrôler la fixation de la borne et
l’absence de corrosionElémentAprès
rodageA cha-
que
course
Toutes les
trois cour-
ses (ou
500 km)Toutes les
cinq courses
(ou
1.000 km)Si
néces-
saireRemarques
PROGRAMME D’ENTRETIEN
3 - 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.1-21
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.3-25 ~ 31
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-32 ~ 35
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-43 ~ 44
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-44 ~ 46
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-35 ~ 42
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.3-32
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.1-26
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 ~ 20

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:
1.20 L (1.06 Imp qt, 1.27 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 mini-
mum marks on the tank.
LOWFULLCOOLANTa