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Yamaha WR450F 2-TRAC Supplementary Owner's Service Manual
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Yamaha WR450F 2-TRAC Supplementary Owner's Service Manual

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SUPPLEMENTARY
OWNER'S SERVICE MANUAL
WR450F(S) 2-TRAC
5TJ-F8199-E0

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Summary of Contents for Yamaha WR450F 2-TRAC

  • Page 1 SUPPLEMENTARY OWNER’S SERVICE MANUAL WR450F(S) 2-TRAC 5TJ-F8199-E0...
  • Page 2 WR450F(S) 2-TRAC SUPPLEMENTARY OWNER’S SERVICE MANUAL © 2004 by Yamaha Motor Italia S.p.A. First edition, March 2004 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Italia S.p.A. is expressly prohibited. Printed in Italy...

  • Page 3: Table Of Contents

    CONTENTS HYDROSTATIC TRANSMISSION ..................2 WHEN DRIVING ......................2 FUNCTION ........................2 ADJUSTMENTS ......................3 ALTERNATE RATIOS (OPTIONS) .................. 3 TOOLS ..........................3 SPECIAL TOOLS ........................4 SPECIFICATIONS ........................6 GENERAL SPECIFICATIONS ..................6 MAINTENANCE SPECIFICATIONS ..................7 CHASSIS ........................7 TIGHTENING TORQUES ....................

  • Page 4: Hydrostatic Transmission

    HYDROSTATIC TRANSMISSION WHEN DRIVING Driving a two wheel driven motorcycle is different from driving a conventional motorcycle. The front wheel drive system, during certain conditions, affects the feeling of the handlebar. In sand, mud and snow the traction is greatly improved. However in conditions with deep ruts and slippery surfaces the two wheel drive system might contribute to that the motorcycle feels heavier and more brutal.

  • Page 5: Adjustments

    ADJUSTMENTS The pulling force, at a given circumstance, can be varied by changing the rear wheel sprocket up or down one tooth. If we increase the no by one tooth the pump rotates faster in relation to the hydraulic motor, thereby increasing the pressure in the system and increasing the pulling force of the front wheel.

  • Page 6: Special Tools

    INFO SPECIAL TOOLS SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ by shape and part number from country to country. In such a case, two types are provided.
  • Page 7 INFO SPECIAL TOOLS Tool No. Tool name/How to use Illustration Soft jaws 90890-XXXXX (0727-03) Use this tool for piston shafts 14-16 mm. Steering damper holder 90890-XXXXX (04957-01) Use this tool for holding the steering damper unit with or without link arm. Puller 90890-XXXXX (04954-01)

  • Page 8: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model name: WR450F ’04 – 2-TRAC (EUROPE) Model code number: 5TJ6 (EUROPE) Dimensions: Overall length 2,171 mm (85.5 in) Overall width 827 mm (32.6 in) Overall height 1,303 mm (51.3 in) Seat height 998 mm (39.3 in) Wheelbase 1,485 mm (58.5 in)

  • Page 9: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Shock absorber travel 300 mm ••• Fork spring free length 467 mm 460 mm Installed length 463 mm (4 mm preload) ••• Collar length – ••• Spring rate (K1) 4.5 N/mm (Left leg), 4.1 N/mm (Right leg) •••...

  • Page 10: Tightening Torques

    SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES Tightening Thread torque Part to be tightened Remarks size · · Carburetor drain plug screw M6 x 0.75 0.25 Engine guards (3, 4) and frame M8 x 1.25 Frame and rear frame (upper) M8 x 1.25 Frame and rear frame (under) M8 x 1.25 Muffler (rear) and frame...

  • Page 11: Cable Routing Diagram

    SPEC CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM ç Fasten the wire harness, rectifi- Fuel tank breather hose Oil tank breather hose er/regulator lead, coolant reser- Clamp Brake hose voir hose and hot starter cable Diode Hose guide to the frame with a plastic lock- Wire harness Carburetor breather hose ing tie and cut off the tie end.
  • Page 12 SPEC CABLE ROUTING DIAGRAM ƒ Fasten the wire harness, TPS ˚ Fasten the neutral switch lead ø Pass the wire harness on the lead (in the wire harness), to the frame with a plastic band outside of the neutral switch starter motor lead and negative ends outward.
  • Page 13 SPEC CABLE ROUTING DIAGRAM Drive chain housing (transmission assy) Pump (transmission assy) Hose (pump/reservoir) Reservoir (transmission assy) Hose (motor/pump) Bracket (reservoir) Clamp Motor (transmission assy)
  • Page 14 SPEC CABLE ROUTING DIAGRAM å Pass the throttle cables, clutch Hot starter cable Coolant reservoir hose cable and hot starter cable Clutch cable Rectifier/regulator lead through the cable guides. Throttle cable (return) Clamp ∫ Pass the throttle cables, clutch Throttle cable (pull) CDI unit lead cable and hot starter cable Ignition coil...
  • Page 15 SPEC CABLE ROUTING DIAGRAM ∂ Pass the carburetor breather © Fasten the rectifier/regulator ∆ Fasten the starter motor lead hose (throttle cable cover) lead to the frame with a plastic and negative battery lead to the through the hose holder. locking tie and cut off the tie cable bracket in its slot with a end.
  • Page 16 SPEC CABLE ROUTING DIAGRAM å Install the brake hose so that its ç If the brake hose contacts the Master cylinder pipe portion directs as shown spring (rear shock absorber), Brake hose holder and lightly touches the projec- correct its twist. Brake hose tion on the caliper.
  • Page 17 SPEC CABLE ROUTING DIAGRAM å Position the starter motor lead, ´ Fasten the coolant reservoir Starter motor lead negative battery lead and wire tank breather hose and coolant Negative battery lead harness in the tank damper slit. reservoir hose to the frame with Wire harness a plastic band.
  • Page 18 SPEC CABLE ROUTING DIAGRAM å Fasten the start switch lead to ∂ Pass the start switch lead in Throttle cable the handlebar with the plastic front of the main switch lead. Clamp bands. ´ Pass the hot starter cable Brake hose ∫...

  • Page 19: Regular Inspection And Adjustments

    If it is pressed in and doesn’t come out again there can be two causes. Either the charge pressure has dropped or oil has leaked out. In both cases bring the motorcycle to a Yamaha Service Centre.

  • Page 20: Steering Damper Adjustment

    INSP STEERING DAMPER ADJUSTMENT STEERING DAMPER ADJUSTMENT The steering damper is a hydraulic damper that counteracts wobble, alleviates shock against the front wheel and prevents head shake/cast by the motorcycle, which gives safer riding. The damper is fitted on the upper fork crown, in the centre over the steering stem 1.
  • Page 21 STEERING DAMPER ADJUSTMENT Damping sweep controls Damping sweep controls 5 are located on each side off the damper body. Damping is in position 2, (12 o´clock), when delivered from Yamaha. This setting is fitted for enduro, motocross and off-road riding. WARNING Always ensure that valve setting is within the permitted ranges.
  • Page 22 Change the fluid regularly. In new dampers after 10 hours riding and then every 20 hours riding. Use only recommended fluid that is tested and ap- proved by Yamaha. We cannot guarantee fully ac- ceptable operation using other fluids. NOTE: Regular maintenance and inspection counteracts possible malfunction.

  • Page 23: Front Fork Rebound Damping Force Adjustment

    INSP FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT The rebound adjuster is located at the top of the fork leg. 1. Adjust: • Rebound damping force By turning the adjuster. ¡ Stiffer Increase the rebound damp- ing force.

  • Page 24: Front Fork Compression Damping Force Adjustment

    INSP FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT The compression adjuster is located at the bottom of the fork leg. 1. Adjust: • Compression damping force By turning the adjuster. ¡ Stiffer Increase the compression damp- ing force.

  • Page 25: Rear Shock Absorber Spring Preload Adjustment

    INSP REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: • Rear frame 3. Loosen: • Locknut 1 4. Adjust: • Spring preload By turning the adjuster 2.

  • Page 26: Rear Shock Absorber Rebound Damping Force Adjustment

    INSP REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: • Rebound damping force By turning the adjuster 1. ¡ Stiffer a Increase the rebound damp- ing force. ¡ Softer b Decrease the rebound damp- ing force.

  • Page 27: Rear Shock Absorber Low Compression Damping Force

    INSP REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • Low compression damping force By turning the adjuster 1. ¡ Stiffer a Increase the low compres- sion damping force. (Turn the adjuster 1 in.) ¡...

  • Page 28: Rear Shock Absorber High Compression Damping Force

    INSP REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • High compression damping force By turning the adjuster 1. ¡ Stiffer a Increase the high compres- sion damping force. (Turn the adjuster 1 in.) ¡...

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Wr450fs 2-trac

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