2009 YAMAHA WR 450F Owners Manual

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Page 9 of 226

YAMAHA WR 450F 2009 Owners Manual TABLE OF CONTENTS
GENERAL INFORMATION1
SPECIFICATIONS2
REGULAR INSPECTION AND
ADJUSTMENTS
3
TUNING4
ENGINE5
CHASSIS6
ELECTRICAL7

Page 10 of 226

YAMAHA WR 450F 2009 Owners Manual CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............. 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING

CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............. 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING OF
CONNECTION .................. 1-3
SPECIAL TOOLS ............. 1-4
CONTROL FUNCTIONS .. 1-8
MULTI-FUNCTION
DISPLAY .......................... 1-9
STARTING AND
BREAK-IN ...................... 1-14
TORQUE-CHECK
POINTS........................... 1-16
CLEANING AND
STORAGE ...................... 1-17
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING TORQUES .. 2-12
LUBRICATION
DIAGRAMS .................... 2-18
CABLE ROUTING
DIAGRAM ....................... 2-20
CHAPTER 3
REGULAR INSPEC-
TION AND AD-
JUSTMENTS
PERIODIC MAINTENANCE
CHART FOR THE EMISSION
CONTROL SYSTEM
(For Canada) .................... 3-1
GENERAL MAINTENANCE
AND LUBRICATION CHART
(For Canada) .................... 3-2
MAINTENANCE
INTERVALS FOR
COMPETITION USE ......... 3-3
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-7
ENGINE ............................ 3-8
CHASSIS ........................ 3-19
ELECTRICAL ................. 3-29
CHAPTER 4
TUNING
ENGINE
(Except for Canada) ........ 4-1
CHASSIS .......................... 4-5
CHAPTER 5
ENGINE
RADIATOR ....................... 5-1
CARBURETOR................. 5-4
AIR INDICTOIN
SYSTEM ......................... 5-13
CAMSHAFTS.................. 5-15
CYLINDER HEAD........... 5-20
VALVES AND VALVE
SPRINGS ........................ 5-23
CYLINDER AND
PISTON ........................... 5-27
CLUTCH ......................... 5-30OIL FILTER ELEMENT
AND WATER PUMP .......5-34
BALANCER ....................5-38
OIL PUMP .......................5-40
KICK SHAFT AND
SHIFT SHAFT .................5-43
AC MAGNETO AND
STARTER CLUTCH........5-48
ENGINE REMOVAL........5-53
CRANKCASE AND
CRANKSHAFT ...............5-57
TRANSMISSION, SHIFT
CAM AND SHIFT FORK .5-63
CHAPTER 6
CHASSIS
FRONT WHEEL AND
REAR WHEEL ..................6-1
FRONT BRAKE AND
REAR BRAKE ..................6-6
FRONT FORK .................6-16
HANDLEBAR..................6-23
STEERING ......................6-27
SWINGARM ....................6-31
REAR SHOCK
ABSORBER ....................6-36
CHAPTER 7
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........7-2
IGNITION SYSTEM...........7-4
ELECTRIC STARTING
SYSTEM............................7-6
CHARGING SYSTEM .....7-14
THROTTLE POSITION
SENSOR SYSTEM .........7-16
LIGHTING SYSTEM .......7-19
SIGNALING SYSTEM.....7-21

Page 11 of 226

YAMAHA WR 450F 2009 Owners Manual 1-1
DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without n

Page 12 of 226

YAMAHA WR 450F 2009 Owners Manual 1-2
MACHINE IDENTIFICATION
MACHINE IDENTIFICATION
There are two significant reasons for
knowing the serial number of your
machine:
1. When ordering parts, you can
give the number to your Yamaha
de

1-2
MACHINE IDENTIFICATION
MACHINE IDENTIFICATION
There are two significant reasons for
knowing the serial number of your
machine:
1. When ordering parts, you can
give the number to your Yamaha
dealer for positive identification of
the model you own.
2. If your machine is stolen, the au-
thorities will need the number to
search for and identify your ma-
chine.
VEHICLE IDENTIFICATION
NUMBER
The vehicle identification number "1"
is stamped on the right of the steering
head pipe.
ENGINE SERIAL NUMBER
The engine serial number "1" is
stamped into the elevated part of the
right-side of the engine.
MODEL LABEL
The model label "1" is affixed to the
frame under the rider's seat. This in-
formation will be needed to order
spare parts.
INCLUDED PARTS
VALVE JOINT
This valve joint "1" prevents fuel from
flowing out and is installed to the fuel
tank breather hose.
In this installation, make sure the
arrow faces the fuel tank and also
downward.
SPARK PLUG WRENCH
This spark plug wrench "1" is used to
remove and install the spark plug.
NIPPLE WRENCH
This nipple wrench "1" is used to
tighten the spoke.
JET NEEDLE PULL-UP TOOL
(Except for Canada)
The jet needle pull-up tool "1" is used
to pull the jet needle out of the carbu-
retor.
DRIVE CHAIN SPROCKET GUIDE
(For EUROPE)
Use the drive chain sprocket guide
"1" when installing the included drive
sprockt (13T).
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
AND DISASSEMBLY
1. Remove all dirt, mud, dust, and
foreign material before removal
and disassembly.
• When washing the machine with
high pressured water, cover the
parts follows.
Silencer exhaust port
Side cover air intake port
Water pump housing hole at the
bottom
Drain hole on the cylinder head
(right side)
All electrical components
2. Use proper tools and cleaning
equipment. Refer to "SPECIAL
TOOLS" section.
3. When disassembling the ma-
chine, keep mated parts together.
They include gears, cylinders,
pistons, and other mated parts
that have been "mated" through
normal wear. Mated parts must
be reused as an assembly or re-
placed.

Page 13 of 226

YAMAHA WR 450F 2009 Owners Manual 1-3
CHECKING OF CONNECTION
4. During the machine disassembly,
clean all parts and place them in
trays in the order of disassembly.
This will speed up assembly time
and help assure that all parts a

1-3
CHECKING OF CONNECTION
4. During the machine disassembly,
clean all parts and place them in
trays in the order of disassembly.
This will speed up assembly time
and help assure that all parts are
correctly reinstalled.
5. Keep away from fire.
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha
genuine parts for all replace-
ments. Use oil and/or grease rec-
ommended by Yamaha for
assembly and adjustment.
GASKETS, OIL SEALS AND O-
RINGS
1. All gaskets, oil seals, and O-rings
should be replaced when an en-
gine is overhauled. All gasket sur-
faces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and
bearings during reassembly. Ap-
ply grease to the oil seal lips.
LOCK WASHERS/PLATES AND
COTTER PINS
1. All lock washers/plates "1" and
cotter pins must be replaced
when they are removed. Lock
tab(s) should be bent along the
bolt or nut flat(s) after the bolt or
nut has been properly tightened.BEARINGS AND OIL SEALS
1. Install the bearing(s) "1" and oil
seal(s) "2" with their manufactur-
er's marks or numbers facing out-
ward. (In other words, the
stamped letters must be on the
side exposed to view.) When in-
stalling oil seal(s), apply a light
coating of lightweight lithium base
grease to the seal lip(s). Oil the
bearings liberally when installing.
Do not use compressed air to spin
the bearings dry. This causes dam-
age to the bearing surfaces.
CIRCLIPS
1. All circlips should be inspected
carefully before reassembly. Al-
ways replace piston pin clips after
one use. Replace distorted cir-
clips. When installing a circlip "1",
make sure that the sharp-edged
corner "2" is positioned opposite
to the thrust "3" it receives. See
the sectional view.
CHECKING OF
CONNECTION
Dealing with stains, rust, moisture,
etc. on the connector.
1. Disconnect:
• Connector2. Dry each terminal with an air
blower.
3. Connect and disconnect the con-
nector two or three times.
4. Pull the lead to check that it will
not come off.
5. If the terminal comes off, bend up
the pin "1" and reinsert the termi-
nal into the connector.
6. Connect:
• Connector
The two connectors "click" together.
7. Check for continuity with a tester.
• If there in no continuity, clean the
terminals.
• Be sure to perform the steps 1 to 7
listed above when checking the
wire harness.
• For a field remedy, use a contact re-
vitalizer available on the market.
• Use the tester on the connector as
shown.

Page 14 of 226

YAMAHA WR 450F 2009 Owners Manual 1-4
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will
help prevent damage caused by the use of imp

Page 15 of 226

YAMAHA WR 450F 2009 Owners Manual 1-5
SPECIAL TOOLS
Damper rod holder
YM-01494, 90890-01494Use this tool to remove and install
the damper rod.
Fork seal driver
YM-A0948, 90890-01502 This tool is used when install the fork
oil seal.

Page 16 of 226

YAMAHA WR 450F 2009 Owners Manual 1-6
SPECIAL TOOLS
Valve spring compressor
YM-4019, 90890-04019 This tool is needed to remove and
install the valve assemblies.
Clutch holding tool
YM-91042, 90890-04086 This tool is used to hold the

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