. Read this manual carefully before operating this vehicle. OWNER’S MANUAL WR450F 1DX-28199-E1. EAU46090 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your WR450F.

1. Service Manual
2. Service Manual Pdf

The Owner’s Manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. IMPORTANT MANUAL INFORMATION EAU10133 Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol.

It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

IMPORTANT MANUAL INFORMATION EAU10200 WR450F OWNER’S MANUAL ©2012 by Yamaha Motor Co., Ltd. 1st edition, July 2012 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. Is expressly prohibited. Printed in Japan.

TABLE OF CONTENTS SAFETY INFORMATION.1-1 Ignition circuit cut-off system.3-19 Checking the throttle grip free play.6-17 DESCRIPTION.2-1 FOR YOUR SAFETY – Valve clearance.6-18 Left view. 2-1 PRE-OPERATION CHECKS. TABLE OF CONTENTS Checking the steering.6-30 Checking the wheel bearings.6-30 Battery. 6-30 Replacing the fuse.6-32 Replacing the headlight bulb.6-32 Tail/brake light.6-34 Replacing a turn signal light bulb.

6-34 Replacing the license plate light bulb. SAFETY INFORMATION EAU53004 Take a training course.

Beginners replaced with non-specified com- should receive training from a cer- ponents, the vehicle will no longer tified instructor. Contact an autho- meet the regulations. Be a Responsible Owner  rized motorcycle dealer to find out Watch carefully for other vehicles As the vehicle’s owner, you are respon- about the training courses nearest. SAFETY INFORMATION motorist’s blind spot.

Always obey the speed limit and could contribute to an impairment. Never maintain a motorcycle never travel faster than warrant- of vision that could delay seeing a without proper knowledge. Con- ed by road and traffic conditions. Yamaha accessories, which are avail- When loading within this weight limit, ports. Able only from a Yamaha dealer, have keep the following in mind:  Do not run engine outdoors where been designed, tested, and approved . SAFETY INFORMATION mended by Yamaha, even if sold and sion travel, steering travel or con- electric failure could result, which installed by a Yamaha dealer.

Trol operation, or obscure lights or could cause a dangerous loss of reflectors. Lights or engine power. SAFETY INFORMATION tie-downs or suitable straps that are attached to solid parts of the motorcycle, such as the frame or upper front fork triple clamp (and not, for example, to rubber-mount- ed handlebars or turn signals, or parts that could break). Choose the location for the straps carefully so the straps will not rub against painted surfaces during transport. DESCRIPTION EAU10410 Left view 1, 2 4, 5 6 1.

Front fork compression damping force adjusting screw (page 3-14) 8. Shift pedal (page 3-8) 2. Bleed screw (page 3-15) 9.

Engine oil filler cap (page 6-8) 3. Starter knob (page 3-12) 10.Engine oil drain bolt (oil tank) (page 6-8) 4. DESCRIPTION EAU10420 Right view 1, 2 1. Shock absorber assembly compression damping force adjusting 7. Coolant drain bolt (page 6-13) screw (for slow compression damping) (page 3-16) 8. Brake pedal (page 3-9) 2.

Shock absorber assembly compression damping force adjusting nut 9. DESCRIPTION EAU10430 Controls and instruments 1.

Clutch lever (page 3-8) 8. Throttle grip (page 6-17) 2. Left handlebar switches (page 3-7) 3. Multi-function display (page 3-2) 4.

Main switch (page 3-1) 5. Front brake fluid reservoir (page 6-23) 6.

Right handlebar switches (page 3-7) 7. INSTRUMENT AND CONTROL FUNCTIONS EAU10451 EAU52471 EAU49392 Main switch Indicator lights and warning All electrical systems are off.

Lights EWA16130 WARNING Never push the main switch to “OFF” while the vehicle is moving, otherwise the electrical systems will be switched off, which may result in loss of control or an accident. “ON”, or if the warning light remains This warning light comes on when the operator and increase the risk of an on, have a Yamaha dealer check the fuel level drops below approximately accident. Electrical circuit. INSTRUMENT AND CONTROL FUNCTIONS last set to zero) ton until the display changes after  a clock the main switch is pushed to “ON”. Measurement mode: Basic mode  a speedometer  a distance-compensation tripme- Odometer and tripmeter modes ter (which shows the accumulated Push the “SLCT 2”.

INSTRUMENT AND CONTROL FUNCTIONS push either select button to set the Changing from the basic mode to hours. The measurement mode 3. Push the “RST” button, and the With the odometer selected, push the minute digits will start flashing. “SLCT 1” button and “SLCT 2” button 4.

INSTRUMENT AND CONTROL FUNCTIONS Auto start 1. Push the “SLCT 1” button for at Starting measurement consists of the least two seconds to set the auto following two starts, either of which can start.  Manual start Starting measurement by the rider When the stopwatch is set to auto start, himself operating the button. Resetting the distance-compensation specified. For further information con- tripmeter cerning the use of this meter, please 1.

Check that the stopwatch mea- consult your nearby Yamaha dealer. Surement is in operation. Calibrate the distance-compensation 2. Reset the distance-compensation tripmeter as follows. INSTRUMENT AND CONTROL FUNCTIONS EAU1234B EAU12400 with the starter. See page 5-1 for start- Handlebar switches Dimmer switch “ ” ing instructions prior to starting the en- Set this switch to “ ” for the high gine.

Left beam and to “ ”. INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12871 EAU41264 Clutch lever Shift pedal Brake lever The brake lever is located on the right side of the handlebar. To apply the front brake, pull the lever toward the throttle grip. Clutch lever 1. INSTRUMENT AND CONTROL FUNCTIONS 3. While holding the lever pushed EAU12941 EAU13182 Brake pedal Fuel tank cap away from the throttle grip, turn the adjusting bolt in direction (a) to in- crease the distance, and in direc- tion (b) to decrease it.

Distance between the brake lever and the throttle grip: Minimum (shortest). Gasoline is poisonous and can Your Yamaha engine has been de- heat from the engine or the sun cause injury or death. Handle gaso- signed to use premium unleaded gaso- can cause fuel to spill out of the line with care. INSTRUMENT AND CONTROL FUNCTIONS spark plug life and reduce maintenance EAU41360 EAU13433 Fuel tank breather hose Catalytic converter costs. This model is equipped with a catalytic converter in the exhaust system.

EWA10862 WARNING The exhaust system is hot after op- eration. INSTRUMENT AND CONTROL FUNCTIONS converter.

EAU53230 EAU13650 Starter knob Kickstarter 1. Starter knob/idle adjusting screw 1. Kickstarter lever Starting a cold engine requires a richer To start the engine, fold out the kick- air-fuel mixture, which is supplied by starter lever, move it down lightly with the starter. INSTRUMENT AND CONTROL FUNCTIONS EAU53100 rection.

EAU53200 Steering lock Seat 3. Remove the key. Never ride with the key inserted To remove the seat into the steering lock, which Remove the bolts, and then slide the may result in loss of control and seat to the rear and pull upward. INSTRUMENT AND CONTROL FUNCTIONS To install the seat EAU52450 Adjusting the front fork 1. Fit the slot in the seat onto the pro- EWA10180 jection on the fuel tank.

WARNING Always adjust both fork legs equal- ly, otherwise poor handling and loss of stability may result. INSTRUMENT AND CONTROL FUNCTIONS each fork leg in direction (b). To obtain a precise adjustment, EAU14793 Front fork bleeding it would be advisable to check the num- EWA10200 ber of clicks of each damping force ad- WARNING justing mechanism and to modify the Always bleed both fork legs, other- specifications as necessary. Maximum (hard): Spring preload Distance A = 222 mm (8.74 in) Spring preload adjustment should be made by a Yamaha dealer, since this Rebound damping force service requires special tools and tech- To increase the rebound damping force nical skills. The specified settings are and thereby harden the rebound damp- listed below. INSTRUMENT AND CONTROL FUNCTIONS sion damping force and thereby soften sion damping, turn the adjusting screw the compression damping, turn the ad- in direction (a).

Service Manual

To decrease the com- justing bolt in direction (b). Pression damping force and thereby soften the compression damping, turn the adjusting screw in direction (b). INSTRUMENT AND CONTROL FUNCTIONS visable to check the actual total number absorber assembly to a Yamaha EAU15305 Sidestand of clicks or turns of each damping force dealer for any service. The sidestand is located on the left side adjusting mechanism.

This adjustment of the frame. INSTRUMENT AND CONTROL FUNCTIONS Yamaha dealer repair it if it does not EAU52861 Ignition circuit cut-off system function properly.

The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions. INSTRUMENT AND CONTROL FUNCTIONS WARNING With the engine turned off: 1. Move the sidestand down. If a malfunction is noted, have a Yamaha 2. Make sure that the engine stop switch is set to “ ”. Dealer check the system before riding.

If necessary, add recommended coolant to specified level. 6-12. Check cooling system for leakage.

Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check brake pads for wear. Front brake. Replace if necessary. Make sure that operation is smooth.

Check throttle grip free play. Throttle grip 6-17, 6-27. If necessary, have Yamaha dealer adjust throttle grip free play and lubricate cable and grip housing. Make sure that operation is smooth. Control cables 6-27. Tighten if necessary. Instruments, lights, signals.

Check operation. — and switches. Correct if necessary. Check operation of ignition circuit cut-off system. Sidestand switch 3-18. If system is not working correctly, have Yamaha dealer check vehicle.  a lean angle sensor to stop the en- celerate hard when the engine is understand, ask your Yamaha dealer.

Gine in case of a turnover. In this cold!

EWA10271 case, the multi-function display in. Use the kickstarter when the ambient light should come on. If not, ask a temperature is below 10 C (50 F) or Yamaha dealer to check the elec- when at high altitude. Trical circuit. When the engine is warm, turn the 3. OPERATION AND IMPORTANT RIDING POINTS EAU52971 EAU16671 Starting a warm engine Shifting If the engine fails to start, push the main Follow the same procedure as for start- switch to “OFF” and give the kickstarter ing a cold engine with the exception 10 to 20 slow kicks at full throttle in or- that the starter is not required when the der to clear the engine of the rich air-fu. Do not rev the engine while shifting you are not familiar with vehicle ser-  Always use the clutch while down, and avoid high engine vice, have a Yamaha dealer perform changing gears to avoid damag- speeds with no load on the engine.

EWA10311 for about 10 to 15 more minutes. Period, immediately have a WARNING The motorcycle will now be ready Yamaha dealer check the vehi-  Since the engine and exhaust to ride normally.

System can become very hot. – possibly leading to pending on the weather, terrain, geo- that is certified (if applicable). Yamaha death. See page 1-2 for more in- graphical location, and individual use, dealers are trained and equipped to.

If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. From 7000 km (4200 mi) or 9 months, repeat the maintenance intervals starting from 3000 km (1800 mi) or 3 months.  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. PERIODIC MAINTENANCE AND ADJUSTMENT EAU52581 General maintenance and lubrication chart ODOMETER INITIAL READINGS ANNUAL 3000 km 5000 km ITEM CHECKS AND MAINTENANCE JOBS 1000 km CHECK (1800 mi) (3000 mi) (600 mi) or or 3 or 6 1 month months months. PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER INITIAL READINGS ANNUAL 3000 km 5000 km ITEM CHECKS AND MAINTENANCE JOBS 1000 km CHECK (1800 mi) (3000 mi) (600 mi) or or 3 or 6 1 month months months.

Check bearing play and steering for roughness. PERIODIC MAINTENANCE AND ADJUSTMENT ODOMETER INITIAL READINGS ANNUAL 3000 km 5000 km ITEM CHECKS AND MAINTENANCE JOBS 1000 km CHECK (1800 mi) (3000 mi) (600 mi) or or 3 or 6 1 month months months. Check hoses for cracks of damage. Do not attempt to diagnose 1. Panel A such problems yourself.

Instead, have EAU52872 a Yamaha dealer check the vehicle. If the spark plug shows signs of elec- trode erosion and excessive carbon or Panel A other deposits, it should be replaced. PERIODIC MAINTENANCE AND ADJUSTMENT wire thickness gauge and, if necessary, past finger tight. However, the spark EAU52964 Engine oil and oil filter adjusted to specification. Plug should be tightened to the speci- element fied torque as soon as possible. The engine oil level should be checked before each ride.

PERIODIC MAINTENANCE AND ADJUSTMENT And do not touch the radiator pipe after high-speed operation, otherwise the cooling system is hot and cause burns. Always let the engine oil cool down suffi- ciently before removing the oil tank cap. NOTICE: Do not EWA16140 operate the vehicle until you know that the engine oil level is. PERIODIC MAINTENANCE AND ADJUSTMENT 6. Install the engine oil tank cap, and and the engine oil filler cap.

Then the check bolt and its gasket. To change the engine oil (with or without oil filter element replace- ment) 1. Place the vehicle on a level sur- face.

PERIODIC MAINTENANCE AND ADJUSTMENT Tightening torques: Engine oil drain bolt (oil tank): Skip steps 8–10 if the oil filter element 20 Nm (2.0 mkgf, 14 ftlbf) is not being replaced. Engine oil drain bolt (crank case): 20 Nm (2.0 mkgf, 14 ftlbf) 8. If this occurs,  Make sure that no foreign mate- have a Yamaha dealer repair the EAUM1295 rial enters the crankcase. To check the coolant level . The coolant should be at the bottom of sion. If water has been added to the radiator filler neck.

The level will the coolant, have a Yamaha change with variation of engine temper- 1. Coolant drain bolt dealer check the antifreeze con- ature. Start the engine, and then check the vehicle for coolant leakage. If coolant is leaking, have a Yamaha dealer check the cooling system. Holding clip 2.

Air filter element 3. Recommended oil: erly seated in the air filter case. Yamaha foam air filter oil or other The engine should never be op- quality foam air filter oil erated without the air filter ele- 1. PERIODIC MAINTENANCE AND ADJUSTMENT 1. Holding clip 1. Air filter check hose 2.

Projection 2. Projection 2. If dirt or water is visible, remove 3. Air filter element 8.

Close the air filter case cover, and the hose, clean it, and then install 7. Yamaha dealer make the adjustment. Turn the screw in direction (a).

To and, if necessary, have a Yamaha decrease the engine idling speed, dealer adjust it. Turn the screw in direction (b). Tire air pressure (measured on cold from occurring, the valve clearance small area of road contact. Therefore, it tires): must be adjusted by a Yamaha dealer is essential to maintain the tires in good 0–90 kg (0–198 lb): Front: at the intervals specified in the periodic condition at all times and replace them 150 kPa (1.50 kgf/cm. Yamaha dealer re-  The replacement of all wheel- place the tire immediately. If any damage is found, have a Yamaha dealer replace the wheel. Do not attempt even the smallest repair to the wheel.

A de- formed or cracked wheel must be replaced. No brake lever free play (b). There should be no free play at the brake lever end. If there is free play, have a Yamaha dealer inspect the brake system. EWA14211 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. Brake light switches dent.

The operation of the shift pedal should be checked before each ride. If opera- tion is not smooth, have a Yamaha dealer check the vehicle. Rear brake light switch 2. Rear brake light switch adjusting nut. PERIODIC MAINTENANCE AND ADJUSTMENT EAU22392 peared, have a Yamaha dealer replace EAU22581 Checking the front and rear Checking the brake fluid level the brake pads as a set. Brake pads Before riding, check that the brake fluid is above the minimum level mark. Rear brake may deteriorate, causing leak- EAU52952 Changing the brake fluid age.

Have a Yamaha dealer change the  Refill with the same type of brake fluid at the intervals specified in brake fluid. Adding a brake fluid the periodic maintenance and lubrica- other than DOT 4 may result in a tion chart. EAU34317 To adjust the drive chain slack 3.

Pull the drive chain up above the Consult a Yamaha dealer before ad- drive chain guard installation bolt justing the drive chain slack. With a force of 50 N (5.0 kgf, 11 1.

PERIODIC MAINTENANCE AND ADJUSTMENT nuts to their specified torques. EAU23025 may contain substances that Cleaning and lubricating the could damage the O-rings. ECA11111 Tightening torques: drive chain Axle nut: The drive chain must be cleaned and 125 Nm (12.5 mkgf, 90 ftlbf) lubricated at the intervals specified in Locknut: the periodic maintenance and lubrica.

Yamaha dealer at the intervals speci- bricated if necessary. Ed if necessary. If a cable is damaged fied in the periodic maintenance chart.

EWA10731 Lithium-soap-based grease WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Otherwise, the sidestand could contact the ground and distract the operator, re- sulting in a possible loss of control. The swingarm pivots must be lubricat- intervals specified in the periodic main- ed by a Yamaha dealer at the intervals tenance and lubrication chart. Specified in the periodic maintenance and lubrication chart. If any free This model is equipped with a VRLA the wheel bearings. Play can be felt, have a Yamaha (Valve Regulated Lead Acid) battery. Dealer check or repair the steering.

There is no need to check the electro- lyte or to add distilled water. To charge the battery necessary. Have a Yamaha dealer charge the bat- 3. Fully charge the battery before in- tery as soon as possible if it seems to stallation.

NOTICE: When install- have discharged. ECA10650 NOTICE 4.

If the fuse immediately blows Take care not to damage the follow- again, have a Yamaha dealer ing parts: check the electrical system.  Headlight bulb Do not touch the glass part of the headlight bulb to keep it free 1. Have a Yamaha dealer adjust the 1. Do not touch the glass part of the bulb. Headlight beam if necessary.

Remove the headlight cowling to- 1. Remove the turn signal light lens If the tail/brake light does not come on, by removing the screw. Have a Yamaha dealer check it. Turn signal light bulb 3. Insert a new bulb into the socket, push it in, and then turn it clock- wise until it stops.

PERIODIC MAINTENANCE AND ADJUSTMENT EAU24313 EAU45224 Replacing the license plate Replacing an auxiliary light light bulb bulb 1. Remove the license plate light unit If the auxiliary light bulb burns out, re- by removing the screws. Place it as follows. PERIODIC MAINTENANCE AND ADJUSTMENT EAU24350 frame in front of the rear wheel or under Supporting the motorcycle each side of the swingarm. Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or performing other maintenance requiring the motorcycle to stand up- right.

PERIODIC MAINTENANCE AND ADJUSTMENT EAU24360 installing the spacers, be sure Front wheel to install them on the correct side. ECA17700 EAU49332 2.

Lift the wheel up between the fork To remove the front wheel legs. EWA10821 WARNING Make sure that there is enough space To avoid injury, securely support the between the brake pads before install- vehicle so there is no danger of it. PERIODIC MAINTENANCE AND ADJUSTMENT EAU25080 Tightening torque: Rear wheel Front wheel axle pinch bolt: 21 Nm (2.1 mkgf, 15 ftlbf) EAU45183 To remove the rear wheel 8. Push down hard on the handlebar EWA10821 several times to check for proper WARNING fork operation. PERIODIC MAINTENANCE AND ADJUSTMENT into the slot in the swingarm. Tightening torques:  Make sure that there is enough Axle nut: The drive chain does not need to be space between the brake pads be- 125 Nm (12.5 mkgf, 90 ftlbf) disassembled in order to remove and Locknut: fore installing the wheel. The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self.

Service Manual Pdf

However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly. Remove the spark plug and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the compression.

Compression The engine does not start. Have a There is compression. Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

Rust and corrosion can develop Cleaning sure to consult a Yamaha dealer for even if high-quality components are ECA10772 advice on what products to use be- NOTICE used. MOTORCYCLE CARE AND STORAGE off any detergent residue using Test the product on a small hid- remain well into spring. Plenty of water, as it is harmful den part of the windshield to 1. Clean the motorcycle with cold wa- to plastic parts. EWA11131  Consult a Yamaha dealer for ad- WARNING ECA10810 NOTICE vice on what products to use. Contaminants on the brakes or tires . MOTORCYCLE CARE AND STORAGE stabilizer (if available) to prevent pivoting points of all levers and the fuel tank from rusting and the pedals as well as of the sidestand/ fuel from deteriorating.

Perform the following steps to pro- 5.

Online Auto Repair offers service repair manuals for your Yamaha WR450F - DOWNLOAD your manual now!