SUPPLEMENTARY OWNER’S SERVICE MANUAL WR450F(S) 2-TRAC 5TJ-F8199-E0
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.
CONTENTS HYDROSTATIC TRANSMISSION .......................................................................................... WHEN DRIVING .............................................................................................................. FUNCTION ...................................................................................................................... ADJUSTMENTS ..............................................................................................................
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.
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. It must be understood that even the reaction forces in the handlebar increases. From experience the gain is negligible. When decreasing with one/two/three teeth the pulling force is reduced.
SPECIAL TOOLS GEN INFO 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. When placing an order, refer to the list provided below to avoid any mistakes. Tool name/How to use Tool No.
SPECIAL TOOLS Tool name/How to use Tool No. 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) Use this tool for demounting the steering damper linkarm. 90890-XXXXX (04955-01) Sockets 90890-XXXXX (04956-01) Use this tools for mounting the steering damper linkarm.
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model name: WR450F ’04 – 2-TRAC (EUROPE) Model code number: 5TJ6 (EUROPE) Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance 2,171 mm (85.5 in) 827 mm (32.6 in) 1,303 mm (51.3 in) 998 mm (39.3 in) 1,485 mm (58.5 in) 371 mm (14.6 in) Dry weight: Without oil and fuel 128.
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Front suspension: Shock absorber travel Fork spring free length Installed length Collar length Spring rate (K1) Spring rate (K2) Spring stroke (K1) Spring stroke (K2) Optional spring available Quantity Level Recommended oil Inner tube outer diameter 300 mm ••• 467 mm 460 mm 463 mm (4 mm preload) ••• – ••• 4.5 N/mm (Left leg), 4.
MAINTENANCE SPECIFICATIONS SPEC TIGHTENING TORQUES Thread size Part to be tightened Tightening torque N·m Remarks m·kg Carburetor drain plug screw Engine guards (3, 4) and frame Frame and rear frame (upper) Frame and rear frame (under) Muffler (rear) and frame Muffler (middle) and frame Muffler band/exhaust pipe Nut pivot shaft and frame Screw and nut pivot shaft Rear shock absorber upper and frame Rear shock absorber (lower) and arm relay Front fork handle crown and inner tube Front fork under brack
CABLE ROUTING DIAGRAM SPEC CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 9 0 q w e r t Fuel tank breather hose Clamp Diode Wire harness Hot starter cable Negative battery lead Starter motor lead TPS (throttle position sensor) lead Neutral switch lead Oil hose Hose holder Radiator hose 4 Cylinder head breather hose AC magneto lead Radiator hose 1 y u i o t a Oil tank breather hose Brake hose Hose guide Carburetor breather hose Overflow hose Coolant reservoir tank breather å Insert the fuel tank breather hose i
CABLE ROUTING DIAGRAM ƒ Fasten the wire harness, TPS lead (in the wire harness), starter motor lead and negative battery lead to the frame with a plastic locking tie and cut off the tie end. © Make sure that the TPS coupler does not go out the chassis. ˙ Fasten the TPS lead to the frame with a plastic band. ˆ Fasten the neutral switch lead and oil hose together with the plastic locking ties and cut off the tie ends. ∆ Pass the cylinder head breather hose through the hose holders.
CABLE ROUTING DIAGRAM 1 Drive chain housing 2 3 4 5 6 7 8 (transmission assy) Pump (transmission assy) Hose (pump/reservoir) Reservoir (transmission assy) Hose (motor/pump) Bracket (reservoir) Clamp Motor (transmission assy) 11 SPEC
CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 Hot starter cable Clutch cable Throttle cable (return) Throttle cable (pull) Ignition coil Negative battery lead Starter motor lead Coolant reservoir tank breather hose 9 Rectifier/regulator 0 Cable holder q w e r t y u i o p Coolant reservoir hose Rectifier/regulator lead Clamp CDI unit lead CDI unit CDI unit band CDI unit stay (frame) Cable bracket Clamp (transmission hoses) Transmission motor 12 SPEC å Pass the throttle cables, clutch cable and hot starter cabl
CABLE ROUTING DIAGRAM ∂ Pass the carburetor breather hose (throttle cable cover) through the hose holder. ´ Fasten the coolant reservoir tank breather hose and carburetor breather hoses together with a plastic locking tie. ƒ Fasten the grommet of the clutch cable with the cable holder. © Fasten the rectifier/regulator lead to the frame with a plastic locking tie and cut off the tie end.
CABLE ROUTING DIAGRAM 1 Master cylinder 2 Brake hose holder 3 Brake hose å Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the caliper. ∫ Pass the brake hose into the brake hose holders. 14 SPEC ç If the brake hose contacts the spring (rear shock absorber), correct its twist. ∂ Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder.
CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 9 0 Starter motor lead Negative battery lead Wire harness Clamp Taillight lead Coolant reservoir tank breather hose Coolant reservoir hose Positive battery lead Starting circuit cut-off relay Battery å Position the starter motor lead, negative battery lead and wire harness in the tank damper slit. ∫ Fasten the wire harness to the frame with a plastic locking tie and cut off the tie end. ç Do not allow the taillight lead to slacken.
CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 9 0 q w e r Throttle cable Clamp Brake hose Hot starter cable Clutch cable Hose guide Clutch switch lead "ENGINE STOP" button lead Trip meter cable Main switch lead Steering damper cover Main switch Start switch lead Clamp (steering damper cover) å Fasten the start switch lead to the handlebar with the plastic bands. ∫ Fasten the "ENGINE STOP" button lead and clutch switch lead to the handlebar with the plastic bands. ç Pass the brake hose through the hose guides.
MAINTENANCE INTERVALS INSP ADJ REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
STEERING DAMPER ADJUSTMENT INSP ADJ 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.
STEERING DAMPER ADJUSTMENT INSP ADJ 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. NOTE: Both damping sweep controls must always be set in identical positions. Always use positions according to the clock. Suitable starting position: Motocross pos.
STEERING DAMPER ADJUSTMENT INSP ADJ 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 approved by Yamaha. We cannot guarantee fully acceptable operation using other fluids. NOTE: Regular maintenance and inspection counteracts possible malfunction. If the steering damper needs service, Öhlins agents have the proper tools and know-how to solve all technical problems.
FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ 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 damping force. (Turn the adjuster in.) Softer → Decrease the rebound damping force. (Turn the adjuster out.
FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ 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 damping force. (Turn the adjuster in.) Softer → Decrease the compression damping force. (Turn the adjuster out.
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT INSP ADJ 1 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 2 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. Stiffer → Increase the spring preload. (Turn the adjuster 2 in.) Softer → Decrease the spring preload. (Turn the adjuster 2 out.) Spring length (installed): Standard length Extent of adjustment 251.5 mm 246.5~256.
REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT b 1. Adjust: • Rebound damping force By turning the adjuster 1. a Stiffer a → Increase the rebound damping force. Softer b → Decrease the rebound damping force. Extent of adjustment: Maximum Fully turned in position Minimum 40 clicks out (from maximum position) • STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned-in position.
REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the low compression damping force. (Turn the adjuster 1 out.
REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the high compression damping force. (Turn the adjuster 1 out.
