Yamaha Wr 450 F Owners Manual

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INSP
ADJ
FUSE INSPECTION
6. Install:
Battery
Battery band
7. Connect:
Battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1, then the
negative lead 2.
8. Check:
Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
Battery terminal
10. Install:
Seat
EAS00181 
FUSE INSPECTION
CAUTION:
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse. 
1. Remove: 
Seat
Fuse cover
2. Check: 
Continuity
2Reserve fuse
Recommended lubricant
Lithium soap base grease
Checking steps:
Remove the fuse 1.
Connect the pocket tester to the fuse and
check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”. 
Pocket tester 
YU-3112-C/90890-03112
If the pocket tester indicates “∞”, replace
the fuse. 
2
1 
						

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INSP
ADJ
REPLACING THE HEADLIGHT BULBS
3. Replace: 
Blown fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the starting and
ignition systems to malfunction and could
possibly cause a fire. 
4. Install: 
Fuse cover
Seat Replacement steps:
Set the main switch to “OFF”.
Install a new fuse of the correct amperage. 
Set on the switches to verify if the electri-
cal circuit is operational. 
If the fuse immediately blows again, check
the electrical circuit.
ItemsAmperage 
ratingQ’ty
Main fuse 10 A 1
REPLACING THE HEADLIGHT BULBS
1. Remove:
Headlight
Refer to “SEAT, FUEL TANK AND
SIDE COVERS” section in the CHAP-
TER 4.
2. Remove:
Headlight bulb holder cover 1 
3. Detach:
Headlight bulb holder 1 
4. Remove:
Headlight bulb 2 
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb unit it has cooled
down. 
						

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INSP
ADJ
ADJUSTING THE HEADLIGHT BEAMS
5. Install:
Headlight bulb 
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free form oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
6. Attach:
Headlight bulb holder
7. Install:
Headlight bulb holder cover
8. Install:
Headlight
Refer to “SEAT, FUEL TANK AND
SIDE COVERS” section in the CHAP-
TER 4.
New
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
Headlight beam (vertically)
Adjusting steps:
Turn the adjusting screw 1 in direction a
or b.
Direction a  Headlight beam is raised.
Direction b  Headlight beam is lowered. 
						

							 
4 - 1
ENG
 
EC400000 
ENGINE 
EC4R0000 
SEAT, FUEL TANK AND SIDE COVERS 
Extent of removal:  
1  
 Seat removal  
2  
 Fuel tank removal  
3  
 Side covers removal  
4  
 Headlight removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal  
SEAT, FUEL TANK AND SIDE 
COVERS REMOVAL  
Turn the fuel cock to “OFF”.
Disconnect the fuel hose.
1 Seat 1
2 Air scoop (left and right) 2
3 Fitting band 1 Remove on fuel tank side.
4 Bolt (fuel tank) 2
5 Fuel tank 1
6 Side cover (left) 1
Refer to “REMOVAL POINTS”.
7 Side cover (right) 1
8 Headlight coupler 1
9 Headlight 1
13
2
3
4
 
SEAT, FUEL TANK AND SIDE COVERS 
						

							 
4 - 2
ENG
 
REMOVAL POINTS
Side cover  
1. Remove: 
 
Bolt (side cover) 
 
Side cover (left)   
1 
 
Side cover (right)   
2
NOTE:
 
Draw the side cover downward to remove it
because its claws   
a  
 are inserted in the air fil- 
ter case. 
SEAT, FUEL TANK AND SIDE COVERS 
 
 
4  
						

							 
4 - 3
ENG
 
EXHAUST PIPE AND SILENCER 
EC4S0000 
EXHAUST PIPE AND SILENCER 
Å 
 For USA 
ı 
 Except for USA
Extent of removal: 
1  
 Silencer removal  
2  
 Exhaust pipe removal
Extent of removal Order Part name Q’ty Remarks  
EXHAUST PIPE AND 
SILENCER REMOVAL 
Preparation for removal Side cover (right) Refer to “SEAT, FUEL TANK AND SIDE 
COVERS” section.
1 Bolt (clamp) 1 Only loosening.
2 Bolt [silencer (front)] 1
3 Bolt [silencer (rear)] 1
4 Silencer 1
5 Clamp 1
6 Nut (exhaust pipe) 1
7 Bolt (exhaust pipe) 1
8 Exhaust pipe 1
9Gasket
2
2
1
2 
						

							 
4 - 4
ENG
 
EXHAUST PIPE AND SILENCER 
INSPECTION
Exhaust pipe and silencer  
1. Inspect: 
 
Gasket   
1  
 
Damage   
→  
 Replace.
1
 
ASSEMBLY AND INSTALLATION
Exhaust pipe and silencer  
1. Install:  
 
Gasket 
 
Exhaust pipe   
1  
  
 
Nut (exhaust pipe)   
2  
  
 
Bolt (exhaust pipe)   
3  
 
NOTE:
 
First, temporarily tighten the nut (exhaust pipe),
then tighten the bolt (exhaust pipe) 20 Nm
(2.0 m • kg,  14 ft • lb). After that, retighten the
nut (exhaust pipe) 13 Nm (1.3 m • kg, 9.4 ft • lb)
and then the bolt (exhaust pipe) 24 Nm 
(2.4 m • kg, 17 ft • lb).
3
1 2New
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..24 Nm (2.4 m · kg, 17 ft · lb)
 
2. Install: 
 
Clamp  
1 
  
 
Gasket  
2 
  
 
Silencer  
3 
  
 
Washer  
4 
 
Bolt (silencer)  
5 
 
2New 1 3
4
4
5T R..20 Nm (2.0 m · kg, 14 ft · lb)
New
T R..35 Nm (3.5 m · kg, 25 ft · lb) 
						

							 
4 - 5
ENG
 
RADIATOR 
EC450001 
RADIATOR 
Extent of removal: 
1 
 Radiator removal 
2 
 Coolant reservoir removal
Extent of removal Order Part name Q’ty Remarks 
RADIATOR REMOVAL 
Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT” 
section in the CHAPTER 3.
Seat, fuel tank and side cover Refer to “SEAT, FUEL TANK AND SIDE 
COVERS” section.
Exhaust pipe Refer to “EXHAUST PIPE AND 
SILENCER” section.
1 Engine guard 1
2 Panel 2
3 Clamp 8
4 Radiator (right) 1
5 Hose 2 1
6 Hose 3 1
7 Hose 4 1
8 Pipe 2/O-ring 1/1
9 Radiator breather hose 1
10 Radiator (left) 1
11 Hose 1 1
12 Pipe 1/O-ring 1/1
13 Coolant reservoir hose 1
14 Coolant reservoir tank 1
1
2 
						

							 
4 - 6
ENG
 
RADIATOR 
EC456000 
HANDLING NOTE
WARNING
 
Do not remove the radiator cap when the
engine and radiator are hot. Scalding hot
fluid and steam may be blown out under
pressure, which could cause serious
injury.
When the engine has cooled, open the radi-
ator cap by the following procedure:
Place a thick rag, like a towel, over the radi-
ator cap, slowly rotate the cap counter-
clockwise to the detent. This procedure
allows any residual pressure to escape.
When the hissing sound has stopped,
press down on the cap while turning coun- 
terclockwise and remove it. 
EC454000 
INSPECTION 
EC444100 
Radiator 
1. Inspect: 
 
Radiator core  
1 
Obstruction → Blow out with com-
pressed air through rear of the radiator.
Bent fin → Repair/replace.
EC455000
ASSEMBLY AND INSTALLATION
Radiator
1. Install:
Pipe 1 1 
Hose 1 2 
Pipe 2 3 
Hose 3 4 
Hose 4 5 
2. Install:
Hose 2 1 
Radiator (left) 2 
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb) 
						

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ENGRADIATOR
3. Install:
Radiator breather hose 1 
Radiator (right) 2 
Refer to “CABLE ROUTING DIA-
GRAM” section in the CHAPTER 2.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
4. Install:
Panel 1 
Bolt (radiator panel upper) 2 
NOTE:
Fit the hook a on the inner side first into the
radiator.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)