2008 YAMAHA WR 450F engine

1-9
MULTI-FUNCTION DISPLAY
COLD STARTER KNOB
When cold, the engine requires a
richer air-fuel mixture for starting. A
separate starter circuit, which is con-
trolled by the cold starter knob "1",
supplies this mixture. Pull the cold
starter knob out to open the circuit for
starting. When the engine has
warmed up, push it in to close the cir-
cuit.
HOT STARTER LEVER
The hot starter lever "1" is used when
starting a warm engine. Use the hot
starter lever when starting the engine
again immediately after it was
stopped (the engine is still warm).
Pulling the hot starter lever injects
secondary air to thin the air-fuel mix-
ture temporarily, allowing the engine
to be started more easily.
SIDESTAND
This sidestand "1" is used to support
only the machine when standing or
transporting it.
• Never apply additional force to
the sidestand.
• Hold up the sidestand before
starting out.
MULTI-FUNCTION DISPLAY
Be sure to stop the machine before
making any setting changes to the
multi-function display.
The multi-function display is
equipped with the following:
BASIC MODE:
• Speedometer
•Clock
• Two tripmeters (which shows the
distance that has been traveled
since it was last set to zero)
RACE MODE:
• Timer (which shows the time that
has been accumulated since the
start of timer measurement)
• Tripmeter (which shows the accu-
mulated travel distance in timer
measurement)
• Change tripmeter digits (capable of
change to any given ones)
DESCRIPTION
Operation buttons:
1. Select button "SLCT 1"
2. Select button "SLCT 2"
3. Reset button "RST"
Screen display:
4. Tripmeter indicator
5. Tripmeter indicator
6. Timer indicator
7. Clock/Timer
8. Speedometer
9. Odometer/Tripmeter
The operation buttons can be pushed
in the following two manners:
Short push: Push the button. ( )
Long push: Push the button for 2 sec-
onds or more. ( )
BASIC MODE
Changing speedometer display
(for U.K.)
1. Push the "SLCT2" button for 2
seconds or more to change the
speedometer units. The speed-
ometer display will change in the
following order:
MPH→km/h→MPH.Setting the time
1. Push the "SLCT1" button for 2
seconds or more to enter the time
setting mode.
2. Push the "RST" button to change
the display for time indication.
The display will change in the fol-
lowing order:
Hour→Minute→Second→Hour.
The digits capable of setting go on
flashing.
3. Push the "SLCT1" button (plus) or
"SLCT2" button (minus) and
change the time. A long push on
the button will fast-forward the
time.
4. To end the setting, push the
"RST" button for 2 seconds or
more.
• In a 30-second absence of button
operation, the setting will come to
an end with the indicated time.
• To reset the seconds, push the
"SLCT1" button or "SLCT2" button.
Changing odometer and tripmeter
A/B (TRIP A/B)
1. Push the "SLCT2" button to
change the tripmeter display. The
display will change in the follow-
ing order:
Odometer →TRIP A→TRIP B→
TRIP A→Odometer.

1-14
STARTING AND BREAK-IN
STARTING AND BREAK-IN
FUEL
Always use the recommended fuel as
stated below. Also, be sure to use
new gasoline the day of a race.
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to the engine inter-
nal parts such as valves, piston
rings, and exhaust system, etc.
If knocking or pinging occurs, use a
different brand of gasoline or higher
octane grade.
• For refueling, be sure to stop the
engine and use enough care not
to spill any fuel. Also be sure to
avoid refueling close to a fire.
• Refuel after the engine, exhaust
pipe, etc. have cooled off.
HANDLING NOTE
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 oper-
ate the machine in a well-ventilated
area.
• The carburetor on this machine
has a built-in accelerator pump.
Therefore, when starting the en-
gine, 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 be-
cause 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, per-
form the checks in the pre-opera-
tion check list.
AIR FILTER MAINTENANCE
According to "CLEANING THE AIR
FILTER ELEMENT" section in the
CHAPTER 3, apply the foam-air-filter
oil or its equivalent to the element.
(Excess oil in the element may ad-
versely affect engine starting.)
STARTING A COLD ENGINE
This model is equipped with an igni-
tion 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 en-
gine.
1. Inspect the coolant level.
2. Turn the fuel cock to "ON".
3. Push on 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 kick-
starter crank.
If the engine fails to start by pushing
the start switch, release the switch,
wait a few seconds, and then try
again. Each starting attempt should
be as short as possible to preserve
the battery. Do not crank the engine
more than 10 seconds on any one at-
tempt. If the engine does not start
with the starter motor, try using the
kickstarter crank.
• If the starter motor will not turn
when pushing the start switch,
stop pushing it immediately and
kick start the engine in order to
avoid the load on the motor.
• Do not open the throttle while
kicking the kickstarter crank.
Otherwise, the kickstarter crank
may kick back.
7. Return the cold starter knob to its
original position and run the en-
gine at 3,000–5,000 r/min for 1 or
2 minutes.
Since this model is equipped with an
accelerator pump, if the engine is
raced (the throttle opened and
closed), the air/fuel mixture will be too
rich and the engine may stall. Also
unlike a two-stroke engine, this model
can idle.
Do not warm up the engine for ex-
tended periods of time.
STARTING A WARM ENGINE
Do not operate the cold starter knob
and throttle. Pull the hot starter lever
"1" and start the engine by pushing
the start switch or by kicking the kick-
starter crank forcefully with a firm
stroke. As soon as the engine starts,
Release the hot starter lever to close
the air passage.
Restarting an engine after a fall
Pull the hot starter lever and start the
engine. As soon as the engine starts,
Release the hot starter lever to close
the air passage. Recommended fuel:
Premium unleaded
gasoline only with a re-
search octane number
of 95 or higher.

1-15
STARTING AND BREAK-IN
The engine fails to start
Pull the hot starter lever all the way
out and while holding the lever, kick
the kickstarter crank 10 to 20 times to
clear the engine. Then, restart the en-
gine. Refer to "Restarting an engine
after a fall".
Observe the following break-in
procedures during initial operation
to ensure optimum performance
and avoid engine damage.
BREAK-IN PROCEDURES
1. Before starting the engine, fill the
fuel tank with the fuel.
2. Perform the pre-operation checks
on the machine.
3. Start and warm up the engine.
Check the idle speed, and check
the operation of the controls and
the engine stop switch. Then, re-
start the engine and check its op-
eration within no more than 5
minutes after it is restarted.4. Operate the machine in the lower
gears at moderate throttle open-
ings for five to eight minutes.
5. Check how the engine runs when
the machine is ridden with the
throttle 1/4 to 1/2 open (low to me-
dium speed) for about one hour.
6. Restart the engine and check the
operation of the machine through-
out its entire operating range. Re-
start the machine and operate it
for about 10 to 15 more minutes.
The machine will now be ready to
race.
• After the break-in or before each
race, you must check the entire
machine for loose fittings and
fasteners as per "TORQUE-
CHECK POINTS". Tighten all
such fasteners as required.
• When any of the following parts
have been replaced, they must
be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in oper-
ation is necessary.
PISTON, RING, VALVES, CAM-
SHAFTS AND GEARS:
These parts require about 30
minutes of break-in operation at
half-throttle or less. Observe the
condition of the engine carefully
during operation.
Thro
ttle
grip
op-
era-
tion*Cold
start-
er
knobHot
start-
er le-
ver
St
ar
ti
n
g
a
c
ol
d
e
n
gi
n
eAir tempera-
ture = less
than 5 °C (41
°F)Ope
n 3
or 4
time
sON OFF
Air tempera-
ture = more
than 5 °C (41
°F)Non
eON OFF
Air tempera-
ture (normal
temperature)
= between 5
°C (41 °F)
and 25 °C
(77 °F)Non
eON/
OFFOFF
Air tempera-
ture = more
than 25 °C
(77 °F)Non
eOFF OFF
Starting an en-
gine after a long
period of timeNon
eON OFF
Restarting a
warm engineNon
eOFF ON
Restarting an en-
gine after a fallNon
eOFF ON
* Operate the throttle grip before kick
starting.

1-16
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
Frame construction Frame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
Lubrication system Tightening of oil hose clamp

1-17
CLEANING AND STORAGE
CLEANING AND STORAGE
CLEANING
Frequent cleaning of your machine
will enhance its appearance, maintain
good overall performance, and ex-
tend the life of many components.
1. Before washing the machine,
block off the end of the exhaust
pipe to prevent water from enter-
ing. A plastic bag secured with a
rubber band may be used for this
purpose.
2. If the engine is excessively
greasy, apply some degreaser to
it with a paint brush. Do not apply
degreaser to the chain, sprockets,
or wheel axles.
3. Rinse the dirt and degreaser off
with a garden hose; use only
enough pressure to do the job.
Excessive hose pressure may
cause water seepage and contami-
nation of wheel bearings, front
forks, brakes and transmission
seals. Many expensive repair bills
have resulted from improper high
pressure detergent applications
such as those available in coin-op-
erated car washers.
4. After the majority of the dirt has
been hosed off, wash all surfaces
with warm water and a mild deter-
gent. Use an old toothbrush to
clean hard-to-reach places.
5. Rinse the machine off immediate-
ly with clean water, and dry all
surfaces with a soft towel or cloth.
6. Immediately after washing, re-
move excess water from the
chain with a paper towel and lubri-
cate the chain to prevent rust.
7. Clean the seat with a vinyl uphol-
stery cleaner to keep the cover
pliable and glossy.
8. Automotive wax may be applied
to all painted or chromed surfac-
es. Avoid combination cleaner-
waxes, as they may contain abra-
sives.
9. After completing the above, start
the engine and allow it to idle for
several minutes.STORAGE
If your machine is to be stored for 60
days or more, some preventive mea-
sures must be taken to avoid deterio-
ration. After cleaning the machine
thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and
the carburetor float bowl.
2. Remove the spark plug, pour a ta-
blespoon of SAE 10W-30 motor
oil in the spark plug hole, and re-
install the plug. With the engine
stop switch pushed in, kick the en-
gine over several times to coat the
cylinder walls with oil.
3. Remove the drive chain, clean it
thoroughly with solvent, and lubri-
cate it. Reinstall the chain or store
it in a plastic bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the
wheels off the ground.
6. Tie a plastic bag over the exhaust
pipe outlet to prevent moisture
from entering.
7. If the machine is to be stored in a
humid or salt-air environment,
coat all exposed metal surfaces
with a film of light oil. Do not apply
oil to rubber parts or the seat cov-
er.
Make any necessary repairs before
the machine is stored.

2-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name: WR450FX (CDN, AUS, NZ)
WR450F (EUROPE, ZA)
Model code number: 5TJK (CDN)
5TJL (EUROPE)
5TJM (AUS, NZ, ZA)
Dimensions: CDN, ZA AUS, NZ EUROPE
Overall length 2,175 mm (85.63
in) 2,190 mm (86.22
in)2,200 mm (86.61
in)
Overall width 825 mm (32.48 in)←←
Overall height 1,295 mm (50.98
in)1,300 mm (51.18
in)1,305 mm (51.38
in)
Seat height 980 mm (38.58 in) 990 mm (38.98 in)←
Wheelbase 1,485 mm (58.46
in)←1,500 mm (59.06
in)
Minimum ground clearance 365 mm (14.37 in) 370 mm (14.57 in) 375 mm (14.76 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 CDN)
Yamalube 4, SAE10W30 or SAE20W40
Yamalube 4-R, SAE10W50
API service SG type or higher,
JASO standard MA

2-2
GENERAL SPECIFICATIONS
(Except for CDN)
SAE10W30, SAE10W40, SAE15W40,
SAE20W40 or SAE20W50
API service SG type or higher,
JASO standard MA
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: CDN, ZA, AUS, NZ EUROPE
Primary reduction system Gear←
Primary reduction ratio 61/23 (2.652)←
Secondary reduction system Chain drive←
Secondary reduction ratio 50/13 (3.846) 47/14(3.357)
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)←
2

2-4
MAINTENANCE SPECIFICATIONS
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 outside 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)
Intake "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)
Exhaust "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)
Timing chain:
Timing chain type/No. of links 98XRH2010-118M/118 ----
Timing chain adjustment method Automatic ----