2007 YAMAHA WR 450F engine

SPEC
2 - 1
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: WR450FW (USA, CDN, AUS, NZ)
WR450F (EUROPE, ZA)
Model code number: 5TJE (USA)
5TJF (EUROPE)
5TJG (CDN, AUS, NZ, ZA)
Dimensions: USA, ZA, CDN EUROPE, AUS, NZ
Overall length 2,175 mm (85.63 in) 2,190 mm (86.22 in)
Overall width 825 mm (32.48 in)←
Overall height 1,295 mm (50.98 in) 1,300 mm (51.18 in)
Seat height 980 mm (38.58 in) 990 mm (38.98 in)
Wheelbase 1,485 mm (58.46 in)←
Minimum ground clearance 365 mm (14.37 in) 370 mm (14.57 in)
Dry weight:
Without oil and fuel 112.5 kg (248.0 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 449 cm
3 (15.8 Imp oz, 15.2 US oz)
Bore × stroke 95.0 × 63.4 mm (3.74 × 2.50 in)
Compression ratio 12.3 : 1
Starting system Kick and electric starter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For USA and CDN)
Yamalube 4, SAE10W30 or SAE20W40
Yamalube 4-R, SAE10W50
API service SG type or higher,
JASO standard MA
(Except for USA and CDN)
SAE10W30, SAE10W40, SAE15W40,
SAE20W40 or SAE20W50
API service SG type or higher,
JASO standard MA
-20 -10 0 10 20 30 40 50
˚C 0 10 30 50 70 90 110 130
˚F
YAMALUBE 4(10W-30) or SAE 10W-30
YAMALUBE 4(20W-40) or SAE 20W-40
YAMALUBE 4-R(10W-50) or SAE 10W-50
-20 -10 0 10 20 30 40 50
˚C
SAE 10W-30
SAE 10W-40
SAE 15W-40
SAE 20W-40
SAE 20W-50
GENERAL SPECIFICATIONS

SPEC
2 - 2 Oil capacity:
Engine oil
Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt)
With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt)
Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes): 1.0 L (0.88 Imp qt, 1.06 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a
research octane number of 95 or higher.
Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal)
Reserve 1.1 L (0.24 Imp gal, 0.29 US gal)
Carburetor:
Type FCR MX39
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 61/23 (2.652)
Secondary reduction system Chain drive
Secondary reduction ratio 50/13 (3.846)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 29/12 (2.417)
2nd 26/15 (1.733)
3rd 21/16 (1.313)
4th 21/20 (1.050)
5th 21/25 (0.840)
Chassis: USA, ZA, CDN EUROPE, AUS, NZ
Frame type Semi double cradle←
Caster angle 27.3°27.0°
Trail 117 mm (4.61 in) 116 mm (4.57 in)
Tire:
Type With tube
Size (front) 80/100-21 51M (USA, CDN, ZA)
90/90-21 54R (EUROPE, AUS, NZ)
Size (rear) 110/100-18 64M (USA, CDN, ZA)
130/90-18 69R (EUROPE, AUS, NZ)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
GENERAL SPECIFICATIONS

2

SPEC
2 - 4
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm
(0.002 in)
Cylinder:
Bore size 95.00 ~ 95.01 mm
(3.7402 ~ 3.7406 in)----
Out of round limit ---- 0.05 mm
(0.002 in)
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000 ~ 22.021 mm
(0.8661 ~ 0.8670 in)----
Camshaft journal diameter 21.959 ~ 21.972 mm
(0.8645 ~ 0.8650 in)----
Shaft-to-cap clearance 0.028 ~ 0.062 mm
(0.0011 ~ 0.0024 in)0.08 mm
(0.003 in)
Cam dimensions
Intake“A”30.100 ~ 30.200 mm
(1.1850 ~ 1.1890 in)30.000 mm
(1.1811 in)
“B”22.450 ~ 22.550 mm
(0.8839 ~ 0.8878 in)22.350 mm
(0.8799 in)
Exhaust“A”30.200 ~ 30.300 mm
(1.1890 ~ 1.1929 in)30.100 mm
(1.1850 in)
“B”22.450 ~ 22.550 mm
(0.8839 ~ 0.8878 in)22.350 mm
(0.8799 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
A
B
MAINTENANCE SPECIFICATIONS

SPEC
2 - 8 Clutch:
Friction plate thickness 2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)2.8 mm
(0.110 in)
Quantity 8 ----
Clutch plate 1 thickness 1.9 ~ 2.1 mm (0.075 ~ 0.083 in) ----
Quantity 4 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch plate 2 thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) ----
Quantity 3 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch spring free length 50.0 mm (1.97 in) 49.0 mm
(1.93 in)
Quantity 6 ----
Clutch housing thrust clearance 0.10 ~ 0.35 mm
(0.0039 ~ 0.0138 in)----
Clutch housing radial clearance 0.010 ~ 0.044 mm
(0.0004 ~ 0.0017 in)----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm
(0.002 in)
Kickstarter:
Type Ratchet type ----
Carburetor:
I. D. mark 5TJE E0 ----
Main jet (M.J) #162 ----
Main air jet (M.A.J)ø2.0 ----
Jet needle (J.N) NFNT ----
Cutaway (C.A) 1.5 ----
Pilot jet (P.J) #45 ----
Pilot air jet (P.A.J) #70 ----
Pilot outlet (P.O)ø0.9 ----
Bypass (B.P)ø1.0 ----
Valve seat size (V.S)ø3.8 ----
Starter jet (G.S) #65 ----
Leak jet (Acc.P) #60 ----
Float height (F.H) 8 mm (0.31 in) ----
Engine idle speed 1,750 ~ 1,850 r/min ----
Intake vacuum 34.8 ~ 40.1 kPa
(261 ~ 301 mmHg,
10.28 ~ 11.85 inHg)----
Hot starter lever free play 3 ~ 6 mm (0.12 ~ 0.24 in) ----Item Standard Limit
MAINTENANCE SPECIFICATIONS

SPEC
2 - 12
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.
NOTE:
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m  kg, 22 ft  lb) in the proper tightening sequence,
remove and retighten the cylinder head bolts to 20 Nm (2.0 m  kg, 14 ft  lb) in the proper tightening
sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the
proper tightening sequence.Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2
Oil filter cover M6 × 1.0 2 10 1.0 7.2
Oil check bolt (cylinder head) M6 × 1.0 1 10 1.0 7.2
Oil hose clamp—220.21.4
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase cover (right) M6 × 1.0 8 10 1.0 7.2
M6 × 1.0 2 12 1.2 8.7
Crankcase cover (left) M6 × 1.0 8 10 1.0 7.2
Idle gear cover (starter motor) M6 × 1.0 2 10 1.0 7.2
Crankcase M6 × 1.0 12 12 1.2 8.7
Clutch cable holder M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (crankcase right) M10 × 1.25 1 20 2.0 14
(crankcase left) M6 × 1.0 1 20 2.0 14
Oil check bolt (crankcase) M6 × 1.0 1 10 1.0 7.2
Oil strainer M6 × 1.0 1 10 1.0 7.2
Crankcase bearing stopper M6 × 1.0 4 14 1.4 10
Crankcase bearing stopper M6 × 1.0 8 10 1.0 7.2
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter M8 × 1.25 1 33 3.3 24
Screw (kickstarter) M6 × 1.0 1 7 0.7 5.1
Starter clutch M6 × 1.0 6 16 1.6 11
Primary drive gear M20 × 1.0 1 110 11.0 80
Clutch boss M20 × 1.0 1 75 7.5 54
Clutch cable adjust bolt and locknut M8 × 1.0 1 4 0.4 2.9
Clutch spring M6 × 1.0 6 10 1.0 7.2
Balancer M10 × 1.0 1 45 4.5 32
Balancer driven gear M14 × 1.0 1 50 5.0 36
Balancer weight plate M6 × 1.0 3 10 1.0 7.2
Drive sprocket M20 × 1.0 1 75 7.5 54
Drive sprocket cover M6 × 1.0 2 8 0.8 5.8
Shift pedal M6 × 1.0 1 12 1.2 8.7
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
MAINTENANCE SPECIFICATIONS

SPEC
2 - 16 Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Rear wheel axle and nut M20 × 1.5 1 125 12.5 90
Driven sprocket and wheel hub M8 × 1.25 6 50 5.0 36
Nipple (spoke)—72 3 0.3 2.2
Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2
Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
Engine upper bracket and frame M10 × 1.25 4 55 5.5 40
Engine lower bracket and frame M8 × 1.25 4 34 3.4 24
Engine and engine bracket (lower) M10 × 1.25 1 53 5.3 38
Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
Engine and frame (lower) M10 × 1.25 1 53 5.3 38
Engine guard M6 × 1.0 3 7 0.7 5.1
Regulator mounting M6 × 1.0 2 7 0.7 5.1
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
Relay arm and swingarm M14 × 1.5 1 70 7.0 50
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame and frame (upper) M8 × 1.25 1 38 3.8 27
Rear frame and frame (lower) M8 × 1.25 2 32 3.2 23
Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Drive chain tensioner mounting (upper) M8 × 1.25 1 16 1.6 11
Drive chain tensioner mounting (lower) M8 × 1.25 1 16 1.6 11
Chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank mounting M6 × 1.0 2 9 0.9 6.5
Fuel tank and fuel cock M6 × 1.0 2 4 0.4 2.9
Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Seat mounting M8 × 1.25 2 23 2.3 17
Side cover mounting M6 × 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
Air scoop and radiator panel (lower) M6 × 1.0 2 6 0.6 4.3
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting (front) M6 × 1.0 2 7 0.7 5.1
Rear fender mounting (rear) M6 × 1.0 2 11 1.1 8.0
Multi-function display bracket mounting M6 × 1.0 2 7 0.7 5.1
Multi-function display mounting M5 × 0.8 2 4 0.4 2.9
Plate 1 and protector M5 × 0.8 2 4 0.4 2.9
Plate 2 and protector—2 0.5 0.05 0.36
MAINTENANCE SPECIFICATIONS

SPEC
2 - 20
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm mkg ftlb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg
× m/sec
2 Force
Nm
m  kgNewton meter
Meter kilogramN
× m
m
× kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute
—Engine speed
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS

2 - 24
SPECCABLE ROUTING DIAGRAM
ÈInsert the end of the fuel tank breather hose into
the hole in the steering stem.
ÉFasten the throttle cable, hot starter cable and
rectifier/regulator lead onto the frame. Locate
the clamp end facing the lower side of the hot
starter cable and cut off the tie end.
ÊFasten the diode (at the marking), throttle cable
and hot starter cable onto the frame. Locate the
clamp end facing toward the lower right of the
frame and with the tie end facing downward.
ËFasten the wire harness, throttle position sensor
lead and clutch cable onto the frame. Pass the
clamp through the hole in the stay (air cut-off
valve). Locate the clamp end facing toward the
lower side of the frame and cut off the tie end.ÌFasten the throttle position sensor lead onto the
frame. Locate the clamp end facing toward the
lower side of the frame and cut off the tie end.
ÍPass the carburetor breather hoses, carburetor
overflow hose and catch tank breather hose
between the connecting rod and cross tube
(frame).
ÎPass the neutral switch lead on the inside of the
engine bracket.
ÏFasten the neutral switch lead and AC magneto
lead onto the frame. Locate the clamp end fac-
ing toward the outside of the frame and tie end
facing toward the rear of the frame.