Name: Yamaha WR450FB 2012
Brand: Yamaha
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2012-2015

OWNER’S SERVICE MANUAL

WR450FB

1DX-28199-10LIT-11626-25-58

WR450FB

2012

Read this manual carefully before operating this vehicle.

PRINTED ON RECYCLED PAPER PRINTED IN JAPAN

2012.01––1.4 × 1

(E)

1DX-28199-10_Hyoshi.indd 1 2012/01/19 16:15:01

Table of Contents9
General Information11
Location of Important Labels13
Description15
Consumer Information16
Vehicle Identification Number16
Engine Serial Number16
Model Label16
Vehicle Emission Control Information Label16
Features17
Outline of the Fi System17
Fi System18
Included Parts19
Valve Joint19
Spark Plug Wrench19
Nipple Wrench19
Handlebar Protector19
Hook (Fuel Tank)19
Fuel Hose Joint Cover19
Coupler for Connecting Optional Part20
Important Information20
Preparation for Removal and Disassembly20
Replacement Parts20
Gaskets, Oil Seals and O-Rings21
Lock Washers/Plates and Cotter Pins21
Bearings and Oil Seals21
Circlips21
Basic Service Information23
Electrical System23
Special Tools29
Control Functions32
Main Switch32
Indicator Lights and Warning Lights32
Engine Stop Switch32
Start Switch33
Clutch Lever33
Shift Pedal33
Kickstarter Crank33
Throttle Grip33
Front Brake Lever33
Rear Brake Pedal34
Sidestand34
Starter Knob/Idle Adjusting Screw34
Multi-Function Display34
Description34
Basic Mode35
Changeover to Basic Mode/Race Mode36
Race Mode37
Function Diafram41
Starting and Break-In42
Fuel42
Handling Note43
Air Filter Maintenance43
Starting a Cold Engine43
Starting a Warm Engine43
Break-In Procedures44
Torque-Check Points45
Motorcycle Care and Storage46
Care46
Storage47
Specifications49
General Specifications50
Engine Specifications51
Chassis Specifications57
Electrical Specifications60
Tightening Torques62
General Tightening Torque Specifications62
Engine Tightening Torques63
Chassis Tightening Torques66
Lubrication Points and Lubricant Types70
Engine70
Chassis72
Lubrication System Chart and Diagrams74
Lubrication Diagrams74
Cable Routing78
Periodic Checks and Adjustments91
Periodic Maintenance92
Introduction92
Periodic Maintenance Chart for the Emission Control System92
General Maintenance and Lubrication Chart92
Maintenance Intervals for Competition Use94
Checking the Fuel Line97
Checking the Spark Plug97
Adjusting the Valve Clearance98
Cleaning the Air Filter Element100
Checking the Breather Hoses101
Adjusting the Engine Idling Speed102
Checking the Exhaust System103
Checking the Engine Oil Level103
Changing the Engine Oil104
Adjusting the Clutch Lever Free Play106
Checking the Coolant Level106
Checking the Cooling System107
Changing the Coolant107
Cleaning the Spark Arrester108
Checking the Brake Fluid Level108
Adjusting the Front Disc Brake109
Checking the Front Brake Pads109
Adjusting the Rear Disc Brake110
Checking the Rear Brake Pads110
Checking the Rear Brake Pad Insulator110
Bleeding the Hydraulic Brake System111
Checking the Front Brake Hose112
Checking the Rear Brake Hose112
Checking the Wheels112
Checking and Tightening the Spokes112
Checking the Tires113
Checking the Wheel Bearings114
Checking the Swingarm Operation114
Adjusting the Drive Chain Slack114
Lubricating the Drive Chain115
Checking and Adjusting the Steering Head115
Lubricating the Levers116
Lubricating the Pedal116
Lubricating the Sidestand116
Checking the Front Fork116
Adjusting the Front Fork Legs116
Air Bleeding from Front Fork117
Checking the Rear Suspension118
Adjusting the Rear Shock Absorber Assembly118
Checking the Connecting Arm and Relay Arm120
Checking and Lubricating the Cables120
Adjusting the Throttle Grip Free Play120
Checking the Chassis Fasteners121
Checking and Charging the Battery121
Tuning123
Chassis124
Selection of the Secondary Reduction Ratio (Sprocket)124
Drive and Rear Wheel Sprockets Setting Parts124
Tire Pressure124
Front Fork Setting125
Change in Amount and Characteristics of Fork Oil125
Setting of Spring after Replacement125
Front Fork Setting Parts126
Rear Suspension Setting126
Choosing Set Length126
Setting of Spring after Replacement127
Rear Shock Absorber Setting Parts128
Suspension Setting (Front Fork)129
Suspension Setting (Rear Shock Absorber)131
General Chassis138
Removing the Side Cover138
Front Wheel140
Removing the Front Wheel140
Checking the Front Wheel140
Disassembling the Front Wheel141
Assembling the Front Wheel141
Installing the Front Wheel (Disc)142
Rear Wheel145
Removing the Rear Wheel145
Checking the Rear Wheel145
Disassembling the Rear Wheel145
Checking and Replacing the Rear Wheel Sprocket145
Assembling the Rear Wheel146
Installing the Rear Wheel (Disc)147
Front Brake151
Introduction154
Checking the Front Brake Disc154
Replacing the Front Brake Pads155
Removing the Front Brake Caliper156
Disassembling the Front Brake Caliper156
Checking the Front Brake Caliper156
Assembling the Front Brake Caliper157
Installing the Front Brake Caliper157
Removing the Front Brake Master Cylinder158
Checking the Front Brake Master Cylinder158
Assembling the Front Brake Master Cylinder158
Installing the Front Brake Master Cylinder159
Rear Brake163
Introduction166
Checking the Rear Brake Disc166
Replacing the Rear Brake Pads166
Removing the Rear Brake Caliper167
Disassembling the Rear Brake Caliper167
Checking the Rear Brake Caliper168
Assembling the Rear Brake Caliper168
Installing the Rear Brake Caliper168
Removing the Rear Brake Master Cylinder169
Checking the Rear Brake Master Cylinder170
Assembling the Rear Brake Master Cylinder170
Installing the Rear Brake Master Cylinder170
Handlebar173
Removing the Handlebar173
Checking the Handlebar173
Installing the Handlebar173
Front Fork181
Removing the Front Fork Legs181
Disassembling the Front Fork Legs181
Checking the Front Fork Legs182
Assembling the Front Fork Legs183
Installing the Front Fork Legs189
Steering Head193
Removing the Lower Bracket193
Checking the Steering Head193
Installing the Steering Head193
Rear Shock Absorber Assembly198
Handling the Rear Shock Absorber198
Disposing of a Rear Shock Absorber198
Removing the Rear Shock Absorber Assembly198
Checking the Rear Shock Absorber Assembly198
Checking the Connecting Arm and Relay Arm199
Installing the Relay Arm199
Installing the Rear Shock Absorber Assembly199
Swingarm201
Removing the Swingarm203
Checking the Swingarm203
Installing the Swingarm204
Chain Drive205
Removing the Drive Chain206
Checking the Drive Chain206
Checking the Drive Sprocket207
Checking the Rear Wheel Sprocket207
Installing the Drive Chain207
Engine209
Engine Removal213
Removing the Engine215
Cleaning the Spark Arrester215
Installing the Engine216
Installing the Exhaust Pipe and Muffler216
Installing the Shift Pedal217
Camshaft218
Removing the Camshaft219
Checking the Camshaft220
Checking the Timing Chain and Camshaft Sprocket222
Checking the Timing Chain Tensioners222
Checking the Decompression System223
Installing the Camshafts223
Cylinder Head225
Removing the Cylinder Head226
Checking the Timing Chain Guide (Exhaust Side)226
Checking the Cylinder Head226
Installing the Cylinder Head227
Valves and Valve Springs230
Removing the Valves230
Checking the Valves and Valve Guides231
Checking the Valve Seats232
Checking the Valve Springs234
Checking the Valve Lifters235
Installing the Valves235
Cylinder and Piston237
Removing the Piston238
Checking the Cylinder and Piston238
Checking the Piston Rings239
Checking the Piston Pin240
Installing the Piston and Cylinder240
Electric Starter242
Checking the Starter Motor244
Assembling the Starter Motor245
Clutch249
Removing the Clutch250
Checking the Friction Plates250
Checking the Clutch Plates250
Checking the Clutch Springs250
Checking the Clutch Housing251
Checking the Clutch Boss251
Checking the Pressure Plate251
Checking the Clutch Push Rods251
Checking the Primary Drive Gear252
Checking the Primary Driven Gear252
Installing the Clutch252
Kickstater256
Removing the Kick Shaft Assembly256
Checking the Kick Shaft and Ratchet Wheel256
Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel256
Installing the Kick Shaft Assembly256
Installing the Kick Idle Gear257
Shift Shaft258
Removing the Segment260
Checking the Shift Shaft260
Checking the Stopper Lever260
Installing the Segment260
Installing the Stopper Lever260
Installing the Shift Guide and Shift Lever Assembly261
Installing the Shift Shaft261
Oil Pump and Balancer Gear262
Removing the Balancer265
Checking the Oil Pump265
Assembling the Oil Pump266
Installing the Oil Pump and Balancer Gear266
Generator and Starter Clutch268
Removing the Generator270
Checking the Starter Clutch270
Installing the Starter Clutch271
Installing the Generator271
Crankcase274
Disassembling the Crankcase276
Checking the Timing Chain, Timing Chain Guide, Oil Strainer276
Checking the Crankcase276
Assembling the Crankcase277
Crankshaft Assembly and Balancer Shaft278
Removing the Balancer Shaft279
Removing the Crankshaft Assembly279
Checking the Crankshaft Assembly279
Installing the Crankshaft Assembly280
Cooling System288
Radiator288
Handling Note288
Checking the Radiator288
Installing the Radiator288
Water Pump290
Checking the Water Pump291
Assembling the Water Pump291
Fuel System293
Fuel Tank294
Removing the Fuel Tank296
Removing the Fuel Pump296
Checking the Fuel Pump Body296
Installing the Fuel Pump296
Removing the Fuel Sender297
Checking the Fuel Sender297
Installing the Fuel Sender297
Installing the Fuel Tank298
Checking the Fuel Pressure298
Throttle Body299
Removing the Throttle Body301
Checking the Injector301
Checking the Throttle Body301
Checking the Throttle Body Joint302
Adjusting the Throttle Position Sensor302
Electrical System303
Ignition System306
Circuit Diagram306
Troubleshooting308
Electric Starting System310
Circuit Diagram310
Starting Circuit Cut-Off System Operation312
Troubleshooting314
Charging System316
Circuit Diagram316
Troubleshooting318
Lighting System320
Circuit Diagram320
Troubleshooting322
Signaling System324
Circuit Diagram324
Troubleshooting326
Fuel Injection System328
Circuit Diagram328
Yamaha Diagnostic Tool330
Ecu Self-Diagnostic Function331
Troubleshooting Method333
List of Self-Diagnostic and Fail-Safe Actions334
List of Diagnostic Codes335
Troubleshooting Details337
Fuel Pump System356
Circuit Diagram356
Trouble Shooting358
Electrical Components360
Checking the Switches364
Checking the Bulbs and Bulb Sockets368
Replacing the Headlight Bulb369
Checking the Fuse369
Checking and Charging the Battery370
Checking the Relays373
Checking the Diode374
Checking the Ignition Spark Gap375
Checking the Spark Plug Cap375
Checking the Ignition Coil375
Checking the Crankshaft Position Sensor376
Checking the Lean Angle Sensor376
Checking the Starter Motor Operation377
Checking the Stator Coil377
Checking the Rectifier/Regulator378
Checking the Speed Sensor378
Checking the Fuel Sender378
Checking the Coolant Temperature Sensor379
Checking the Throttle Position Sensor380
Checking the Throttle Position Sensor Input Voltage380
Checking the Intake Air Pressure Sensor381
Checking the Intake Air Temperature Sensor381
Checking the Fuel Injector382
Troubleshooting383
Troubleshooting384
Starting Failures384
Incorrect Engine Idling Speed384
Poor Medium-And-High-Speed Performance385
Faulty Gear Shifting385
Shift Pedal Does Not Move385
Jumps out of Gear385
Faulty Clutch385
Overheating386
Overcooling386
Poor Braking Performance386
Faulty Front Fork Legs386
Unstable Handling386
Faulty Lighting System387

Yamaha WR450FB 2012 User Manual

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Yamaha WR450FB 2012 Specifications

Related product manuals

Brand	Yamaha
Model	WR450FB 2012
Category	Motorcycle
Language	English