Yamaha Wr450fb 2012 Application guide

EAS1DX3003

INTRODUCTION

Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama-

ha's vast experience in the production of pacesetting racing machines. It represents the highest

grade of craftsmanship and reliability that have made Yamaha a leader.

This manual explains operation, inspection, basic maintenance and tuning of your machine. If you

have any questions about this manual oryour machine, please contact your Yamaha dealer.

The design and manufacture of this Yamaha machine fully comply with the emissions standards for

clean air applicable at the date of manufacture. Yamaha has met these standards without reducing

the performance

or

economy of operation ofthe machine. To maintain these high standards, it is im-

portant that you and your Yamaha dealer pay close attention to the recommended maintenance

schedules and operating instructions contained within this manual.

TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

Yamaha continually seeks advancements·in product design and quality. Therefore, whilethis manual

contains the most current product information available at the time of printing, there may be minor

discrepancies between your machine and this manual. Ifyou have any questions concerning this

manual, please consult your Yamaha dealer.

EWA1DX0001

A WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS

MACHINE.

DO

NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL

YOU

HAVE ATTAINED A

SATISFACTORY KNOWLEDGE OF ITSCONTROLS AND OPERATING FEATURES AND UNTIL

YOU HAVE BEEN TRAINED

IN

SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-

TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE

THAT

YOU

SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

EAS1DX3004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This isthe safety alert symbol. Itis used toalertyou topotential personal

&

injury

hazards.Obeyall safetymessages

that

follow

this

symbol

to

avoid

possible

injury

or

death.

-j\

WARNING

jTIP

A WARNING indicatesa hazardous

situation

which,

if

not

avoided,

could

result

in

death

or

serious

injury.

A NOTICE indicates special precautions

that

must

be taken

to

avoid

damage

to

the

vehicle

or

other

property.

IA TIP provides key information to make procedures easier or clearer.

EAS10X3006

YAMAHA

MOTOR

CORPORATION,

U.S.A.

WR

MOTORCYCLE

LIMITED

WARRANTY

Yamaha

Motor

Corporation,

U.S.A

..

hereby

warrants

to

the

original retail purchaser that

the

following.·

components equipped

on

,·new

·Yamaha ·wR,

motoreycles

purchased

from

an

authorized

YamaiJa

motorcYcle

dealer

in

the

continental

United

States will

be

free

from defects

in

materiel

and

workmanship

for

the

period of

time

stated

herein,

subject

to

certain

stated

limitations.

WR.

components.

Included

under

this

warranty

are

the

engine,

frame,

swlngarm,

and

monoshock.

It

Is

understood

that

the

balance

of

the·

WR

components

are

not

covered

by

any

warranty,

expressed

or

implied. The balance of the

comporients.e<julpped

on

the

unit

are

sold

on

an

•as.

is".

.basis•.This warranty applies _to

the

original

pu~ch'aser

only

and

is

not

transferable.

·

THE

PERIOD

OF

WARRANTY

for

the

above-listed

Yamaha

WR

components

as

originally"

Installed

on

the

.unit

shall

be

thirty (30)

days

from

the

date

of.

purchase.

· -

MODELS

EXCLUDED

FROM

WARR~NTY

Include

those· used for non-Yamaha-authorized· renting,

leasing,

or

other

commercial

purposes.

DURING

THE

PERIOD

OF WARRANTY any

authorized

Yamaha

motorcycle

d!!aler.

will,

free

of

charge,

repair

or

replace,

at

Yamaha's

option,

any

part

adjudged

defective

by

Yamaha

due

to

faulty

workmanship

or

material

from

the

factory.

Parts

used

in

warranty

repairs

will

be

warranted

for

the

balance

of.

the

product's

~arranty

period.

All

parts

replaced

under

warranty

become

property

of

Yamaha

Motor

Corporation,

U.S.A.

GENERA~

EXCLUSIONS

from

this

warranty

shall

include any

failures

caused

by:

a.

Installation

of

parts

or

accessories

that

are

.

not

qualitatively··equivalent

to

genuine·

Yamaha

parts.:

b~

Abnormal

strain,

neglect,

or

abuse.

c.

Accident

or

oollision

damage.

d.

Modification

to

original

parts.

e.

Lack

of

proper

maintenance.

f .

Damage

due

to improper

transportation.

SPECIFIC

EXCLUSIONS

from

this warranty shall

include

parts

replaced

due

to

normal

wear

or

routfne

maintenance.

. THE

CUSTOMER'S

RESPONSIBILITY under this

warranty

shall

be

to:

1

~

·

Operate

and

maintain

the

WR

as

specified

In

the

appropriate

Owner's

Service.Manual,

and

2.

Give·

notice

to

an

authorized

Yamaha

motorcycle

dealer of

any

and

all

apparent

defects

within

ten

(10)

days

after

discovery,

and

make

the

machine

available

at

that

time

for

Inspection

and

repairs

at

such

dealer's

place

of

business.

EMISSION

CONTROL

SYSTEM

WARRANTY

Yamaha

Motor

Corporation,

U.S.A.

also

warrants

to

the ultimate . purchaser and

·_

each

subsequent

purchaser of

each

2006

and

later

model

Yamaha

motorcycle

covered

by

this

warranty

that

the

vehicle

is

designed,

built,

and

equipped

so

as

to

conform

at

the

time

of

sale

with

all

U.S.

emissions

standards

applicable

at

the

time of

manufacture

and

that His

free

from

defects

In

materials

and

workmanship

which

would.

cause·

It

not

to

meet

these

standards

within

the

period

listed

lmmediateiy

below.

Failures

other

than

those

resulting

from

defects

in

·material

or

workmanship

which

arise

solely

as

a

result

of

owner

abuse

arid/or

lack

of proper

maintenance

are not

covered

by

this

warranty.

All Off-Road

ModeJs

Thirty

(30)

months

from

the

original

purchase

date

YAMAHA

MOTOR

coRi'ORAnoN,

u.s.A.

MAKES

NO

OTHER

WARRANrv..

OF

ANY .

KIND,

EXPRESSED

OR

IMPLIED.

ALL

..

IMPLIED

WARRANTIES

OF

MERCHANTABILITY

AND

FrrNESS

FOR

A"

PARnCULAR

PURPOSE

WHICH

EXCEED

THE

OBLJGAnONS

AND

nME

LIMITS

STATED

IN

THIS

WARRANTY

ARE

HEREBY

DISCLAIMED

BY

YAMAHA

~OTOR

CORPORAnON,

U.S.A.

AND

EXCLUDED

FROM

THIS

WARRANTY.

SOME

STATES

DO

NOT.Ai.LOW UMrrAnONS

ON

HOW

LONG

AN

IMPLIED

WARRANTY

LASTS,

SO

THE

ABOVE

LJMrrAnON

MA

y

NOTAPPL

y

TO

YOU.

A·LSo·

EXCLUDED

FROM_

THIS

WARRANTY

ARE

ANY

INCIDENTAL

OR

CONSEQUENTIAi..

DAMAGES

.

.INCLUDING

LOSS

OF

USE.

SOME

STATES

DO

NOT

.

ALLOW

THE

EXCLUSION

OR

LIMn'ATION

OF

INCIDENTAL

OR

CONSEQUENT1AL

DAMAGES,

SO

THE

ABOVE

EXCLUSION

MAY

NOT

APPLY

TO

YOU.

,

THIS

WARRANTY

GIVES

YOU

SPEC/RC

LEGAL

RIGHTS,

AND

YOU

MAY

ALSO

HAVE

OTHER

RIGHTS

WHICH

VARY

FRO~

STATE

TO

STAT£

YAMAHA

MOTOR

CORPORATION,

U.S.A.

CUSTOMER

SER'(ICE

Post

Office

Box

6555

Cypress,

California

90630

WARRANTY

QUESTIONS

AND

ANSWERS

a.

What

costs

are

my

responsibility duringtho warranty period7

A. Tho

ctist~mor's

responsibilityincludesall costs

of

normalmaintenance services, non-war-

ranty repairs, accident and collision damage,

an<!

oil, oil filters, airfilters, spark plugs, and

brake shoes

or

pads.

If

your

machine requires warranty service," you

must

take

it

to

any authorized

Yamaha motorcycle dealerWithin tho continental United States.

Bo

sure

to

bring

·

0.

What

are some examples

of

"abnormal"

strain, neglect,

or

abuse7

A.

These terms are general and overlapeach other

in

areas. Specific examples include: Run•

ning

the

machine

without

oil; operating

the

machine

with

a broken

or

damaged part

which causes another part

to

fail, damaga

or

failure due

to

improper or.careless transpor·

tation and or

tie

down:

and so ori.

If

you have any si>eclfic questions on.operation

or

maintenance, please contact your dealer

for

advice.

0.

Does the warranty cover incidental costs such as towing

or

transportation due

to

a fail-

ure?

A.

No.

The warranty

is

limited

to

repair

of

the machine Itself.

0.

MayI perform any

or

all oftho recommended maintenanco shown in the Owner'sService

Manual instead of having the dealer

do

them?

A. Yes,

if

you are a qualified mechanic and

follow

the procedures specified in the Owner's

Service Manuel. We

do

recommend, however, that items requiring special tools

or

equip·

mentbe done

by

aYamaha motorcycle dealer.

0.

Will

the warranty be void

or

canceled

if

I

do

not

operate

or

maintain

my

new

WR

exact-

ly

as

specified In tho

Ownefs

Service Manual?

A. No. The warranty on a·new motorcycle cannot be

•voided•

or

•cancelled.• However,

If•

particular failure

Is

caua.t

by

operation

or

maintenance

other

then u

shown

In

tho

Owner'sServlco Manuel,

that

failure

may

not

becovered underwarranty.

a.

What responsibility dooa

my

dealer have under

this

warranty?

A. Each Yamaha motorcycle dealer is oxpcctail

to:

1. Completely sot

up

ovary

new

machine before sale.

2. Explain tho oporotlon, maintenance, and

w11rrontv

roqillromonts

to

your

satisfaction

at

1he

time

of

sale, and upon

your

request at anylater date.

In addition, each Yamaha motorcycle dealer Is hold responsible

for

his setup, service

and warranty repair work. ·

a.

Oooa

tho warrenty

on

the engine Include the carburetor. air filter, air box, and exhaust

pipe?

A. No.The warrantycovora onlythe enginecomponents.

·

your

warranty registration identification

or

other valid

proof

of

the original date

of purchase.

If

a question

or

problem arises regarding warranty,

first

contact the .

owner

of

tho dealer-ship. Since all warranty matters are ha.ndled at the dealor

level, this peraon Is in the bast position

to

help you.

If

you

aro·stin not satisfied

and require additional assistai:ico, please

ws:ite:

YAMAHA

MOTOR

CORPORATION

U.S.A.

CUSTOMER

RELATIONS

DEPARTMENT

P.O.

Box

6555

Cypress, California 90630

When contacting Yamaha

Motor

Corporation, U.S.A.

don't

forget

to

include any

important information such

as

names, addresses, model, V.l.N. !frame number),

dates. and receipts.

CHANGE

OF

ADDRESS

The federal government requires each manufacturer

of

a

motor

vehicle

to

main·

tain a complete, up-to-date list

of

all first purchasara against tho possibility

of

11

safety-related defect and recall. This list iscompiled

from

the purchase registra•

tlons sent

to

Yamaha

Motor

Corporation, U.S.A.

by

the selling dealer atthe

time

of

your

purchase.

If

you

should

move

after you have purchased

your

new

motorcycle, please

advise us

of

your new

addre1111

by

sending a postcard listing

your

motorcycle

model name, V.l.N. !frame number), dealer number (or doalo's name! as

it

Is

shown on

your

warranty identification, your

n11me

and

now

mailing address.

Mail to:

YAMAHA

MOTOR

CORPORATION,

U.S.A.

WARRANTY DEPARTMENT

P.O.Box 6555

Cypress, California 90630

This

will

ensure thatYamaha

Motor

Corporation, U.S.A.

hDB

an up·to:date rogis·

trlltion record In accordance

with

federal law.

EAS1DX3005

.

SAFETY INFORMATION

THIS

MACHINE

IS

DESIGNED

STRICTLY

FOR

COMPETITION

USE,.

ONLY

ON

A

CLOSED

COURSE.

It

is

illegal for this

machine

to

be

operated

on

any

public street,

road,

or

highway.

Off-road

use

on

public lands

may

also

be

illegal.

Plea~e

check

local

regulations

before

riding.

•THIS

MACHINE

IS

TO

BE

OPERATED

BY

AN

EXPERIENCED

RIDER

ONLY.

Do

not attempt

to

operate

this machine

at

maximum

power

until

you

are

totally familiar

with

its char-

acteristics.

•THIS

MACHINE

IS

DESIGNED

TO

BE

RIDDEN

BY

THE

OPERATOR

ONLY.

Do

not carry passengers

on

this

machine.

•ALWAYS

WEAR

PROTECTIVE

APPAREL.

When

operating this

machine,

always

wear

an

approved

helmet

with

goggles

or a

face

shield.

Also

wear

heavy

boots,

gloves,

and

protective clothing.

Always

wear proper fitting clothing that

will

not

be

caught

in

any

of

the

moving

parts

or

controls

of

the

machine.

•ALWAYS

MAINTAIN

YOUR

MACHINE

IN

PROPER

WORKING

ORDER.

For

safety

and

reliability, the

machine

must

be

properly maintained.

Always

perform

the

preopera-

tion

checks

indicated

in

this

manual.

Correcting a

mechanical

problem

before

you

ride

may

prevent

an

accident.

•

GASOLINE

IS

HIGHLY

FLAMMABLE.

Always

turn

off

the

engine

while

refueling.

Take

care

to

not spill

any

gasoline

on

the

engine

or

ex-

haust

system.

Never

refuel

in

the

vicinity

of

an

open

flame,

or while

smoking.

•GASOLINE

CAN

CAUSE

INJURY.

If

you

should

swallow

some

gasoline,

inhale

excess

gasoline

vapors,

or

allow

any

gasoline

to

get

into your

eyes,

contact adoctor immediately.

If

any

gasoline spills

onto

your

skin

or clothing,

imme-

diately

wash

skin

areas

with

soap

and

water,

and

change

your clothes.

•ONLY

OPERATE

THE

MACHINE

IN

AN

AREA

WITH

ADEQUATE

VENTILATION.

Never start

the

engine

or

let

it

run

for

any

length of

time

in

an

enclosed

area.

Exhaust

fumes

are

poisonous.

These

fumes

contain

carbon

monoxide,

which

by

itself

is

odorless

and

colorless.

Car-

bon

monoxide

is

a

dangerous

gas

which

can

cause

unconsciousness

or

can

be

lethal.

•

PARK

THE

MACHINE

CAREFULLY;

TURN

OFF

THE

ENGINE.

Always

turn

off

the

engine

if

you

are

going

to

leave

the

machine.

Do

not

park

the

machine

on

a

slope

or

soft

ground

as

it_

may

fall

over.

•THE

ENGINE,

EXHAUST

PIPE,

MUFFLER,

AND

OIL

TANK

WILL

BE

VERY

HOT

AFTERTHE

EN-

GINE

HASfBEEN

RUN.

Be

careful

not

to

touch

them

or

to

allow

any

clothing

item

to

contact

them

during

inspection or

repair.

•

PROPERLY

SECURE

THE

MACHINE

BEFORE

TRANSPORTING

IT.

For

safety,

drain

the

gasoline

from

thefuel tank before transporting

the

vehicle.

EAS10X3008

SYMBOLS

The following symbols are used

in

this manual for easier understanding.

TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

The following symbols are not relevant to every vehicle.

SYMBOL DEFINITION SYMBOL DEFINITION

~

Serviceablewith engine mounted 1 Gear oil

m

~

Filling fluid 1 Molybdenum disulfide oil

~

B Lubricant 1 Brake fluid

A

~

Special tool

-Q»I

Wheel bearing grease

~

Tightening torque

~

Lithium-soap-based grease

~

Wear limit, clearance -cM»t Molybdenum disulfide grease

[0J

Engine speed

-«§»I

Silicone grease

[iJ '

Electrical data

ll

Apply locking agent (LOCTITE®).

1

1111

m Engine oil Replace the part with a new one.

EAS10X3007

HOW TO USE THIS

MANUAL

This manual is intended as a handy, easy-to-read reference bookforthe mechanic. Comprehensive

explanations of all installation, removal, disassembly, assembly, repair and check procedures are

laid out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section

title "1" is shown at the top of each page.

• Sub-section titles "2" appear in smaller print than the section title.

•To

help identify parts and clarify procedure steps, there are exploded diagrams "3" at the start of

each removal and disassembly section.

•Numbers

"4" are given

in

the order of the jobs in the exploded diagram. A number indicates a dis-

assembly step.

• Symbols "5" indicate parts to be lubricated

or

replaced.

Refer to "SYMBOLS".

• A job instruction chart "6" accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

•Jobs

"7" requiring more information (such as special tools and technical data) are described se-

quentially.

5 1

CLUTCH

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KDUSINCI

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TIP

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~-~-~~~--

CLUTCH

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._..,

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~-~

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thtpmwy-..io1

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lil"°"linUUI

...

CffiCICINO

THlPAHSUAI! PU.TI!

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·--

c.--Root-

~=OTHlCl.UTCHPUS>IADDS....._+--+--2

•Putrif0d1•t•

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7

TABLE OF CONTENTS

GENERAL INFORMATION

1

SPECIFICATIONS

2

PERIODIC CHECKS AND ADJUST-

3

TUNING

4

CHASIS

5

ENGINE

6

COOLING SYSTEM

7

FUEL SYSTEM

8

ELECTRICAL SYSTEM

9

TROUBLE SHOOTING

10

MENTS

GENERAL INFORMATION

LOCATION

OF

IMPORTANT LABELS....................................

..

......................1-1

DE

SC

RIPTION

..

...................................

..

.......................................

..

..................1-3

CONSUMER INFORMATION..

..

.......................................

..

.....

..

.....................

..

1

-4

VEHICLE IDENTI

FI

CATION NUMBER ..................

..

..................................1-4

ENGINE SERIAL NUMBER

..

.......

..

...

..

......................

..

................................1-4

MODEL LABEL...........................

..

......................................

..

.

..

...................1-4

VEHICLE EMISSION CONTROL INFORMATION LABEL.........................1-4

FEATURES..............................................................................

..

.......................1-5

OUT

LI

NE OF THE Fl SYSTEM ..............

....

.........................................

..

...

1-5

Fl SYSTEM.................................

..

............................................................1-6

INCLUDED PARTS..

..

.....

..

.....................

..

.....

..

........

..

......

..

......

..

.

..

......

..

.............1-7

VA

LVE JOINT ....

..

...........

..

.

..

...............................

..

.............

..

........

..

...........1-7

SPARK PL

UG

WRENCH.....

..

.....................

..

......................

..

.......

..

..........

..

.1-7

NIPPLE WRENCH...............

..

.....................

..

.......................

..

............

..

.......1-7

HANDLEBAR PROTECTOR ......................................................................1-7

HOOK (FUEL TAN

K)

............

..

............

....

................................................

..

1-7

FUEL HOSE

JO

INT COVER ..

..

...

..

.......................

..........

.

....

.......................1-7

COUPLER FOR CONNEC

TI

NG OPTION

AL

PART ...................................1-8

IMPORTANT INFORMATION............................

..

......................

..

..............

..

.1-8

PREPARATION FOR

RE

MOVAL AND DISASSEMBLY.....................

..

.....1-8

REPLACEMENT PARTS......

..

.......................................

..

...................

..

......1-8

GASKETS, OIL SEALS AND

0-R

INGS ...............

..

....................................1-9

LOCK WASHER

S/

PLA

TE

S AND COTTER PINS ...........

..

.............

....

..

....1-9

BEARINGS AND OIL SEALS ......

....

..................

..

...

..

.......................

..

.........1-9

CIRCLIPS ....

..

.............

..

....

..

........

....

..

....

............

..

....

..

.............

..

...........1-9

BASIC SERVICE INFORMATION ..................................................................

1-1

0

QUICK FASTENERS............

..

.............................

..

...................................1-10

ELECTRICAL SYSTEM ..................

..

...................

..

......

....

..

.................

..

....1-11

SPECIAL TOOLS ..............................................................

..

..............

..

...........1-15

CO

NT

ROL FUNCTIONS.............

..

.....................

..

.....

....

........

..

....

..

..............1-20

MA

IN SWITCH....................

..

.............................

..

.

..

................

..

..........1-20

INDICA

TOR

LI

GHTS AND WARNING

LI

G

HT

S.............................

..

......1-20

E

NG

INE STOP

SW

ITCH .....

..

..............................................................

..

...1-20

START SWITCH

..

.

..

.....

..

...

................

..

...............

..

...........

..

.....

..

...............

1-

21

CL

UT

CH LEVER ....................

..

......

..

.....

..

....................

..

...........

..

........1-21

SHIFT PEDAL.......................

..

..............................

..

.................

..

.............

..

1-

21

KICKSTARTER C.RANK............................................................................

1-21

THROTTLE GRIP.......;

..

~

..........................................................................

1-21

FRONT BRAKE LEVER ...........................................................................

1-21

REAR BRAKE PEDAL..............................................................................1-22

SIDESTAND .............................................................................................1-22

STARTER KNOB/IDLE ADJUSTING SCREW.........................................1-22

MULTl-FUNCTION DISPLAY

..••••..••.......••••••••••••••••••••..•••••.•••••••••.••..•••.•.••••••••

1-22

DESCRIPTION .........................................................................................1-22

BASIC MODE ...........................................................................................1-23

CHANGEOVER TO BASIC MODE/RACE MODE....................................1-24

RACE MODE............................................................................................1-25

FUNCTION DIAFRAM ...............................................................................1-29

STARTING AND BREAK-IN

••••••...••.•.....•••••••••••••••••••••••••.•.•••••.•.•.•.•..•...••••••••.•

1-.30

FUEL.........................................................................................................1-30

HANDLING NOTE ....................................................................................

1-31

AIR FILTER MAINTENANCE ...................................................................

1-31

STARTING A COLD ENGINE ..................................................................

1-31

STARTING A WARM ENGINE.................................................................

1-31

BREAK-IN PROCEDURES ......................................................................1-32

TORQUE-CHECK POINTS

••••••••.•••.••••.•••••••••••••.•••••••.•••.•••••••••.••••••••••••.••••••••••

1-33

MOTORCYCLE CARE

AND

STORAGE

••••••••••••.•.•••••••••••••••••••••••.••..•••••••••••••

1-34

CARE........................................................................................................1-34

STORAGE ................................................................................................1-35

LOCATION OF IMPORTANT LABELS

EASIOX3009

LOCATION OF IMPORTANT LABELS

Pl

ease

read the following importa

nt

labels carefully before operating this

ve

hicle.

USA

1

l

6

Premium unleaded

gasoline onl

y.

3FB·2415E-02

A WARNING

1,2,3

I

This unit contains high pressure nitrogen gas.

Mi

sha

ndling can cause explosion.

• Read owner's manual for instructions.

• Do not in

ci

nerate, puncture or open.

'AA

·22259-80

6 7,8

10 9

7

A WARNING

•BEFORE

YOU

OPERATE THIS VEHICLE, READ

THE OWNER'S MANUAL AND ALL LABELS.

•NEVER CARRY A PASSENGER. You increase

your risk of losing control if you carry a passenger.

•NEVER

OPERATE

THIS

VEHICLE

ON

PUBLIC

ROADS. You can collide with

another

vehicle

if

you

operate

this vehicle on a

public

road.

•ALWAYS WEAR AN APPROVED MOTORCYCLE

HELMET, eye protection, and protective clothing.

•EXPERIENCED RIDER ONLY.

SPA·2

11

8K

-OO

10

1-1

Cold tire

normal

pressure

should

be

set

as

follows

.

FRON

T : 1

OOkPa,

{

1.

00kgl/cm2}' 15psi

REAR

: 1

OOkPa,

1.00k l/cm2 , 15

si

3RV·21668·AO

LOCATION OF IMPORTANT LABELS

CANADA

1

f

2

Premium unleaded

gasoline only. 3FB-2415E-02 I

I Essence supersans J

plomb seulement.

3FB-2415E·12

3

THIS

VEHIC

LE IS A RESTRICTED USE

MOTORCYCLE AND

IS

NOT

INTENDED

FOR

USE ON PUBLIC HIGHWAYS.

CE

VEHICULE

EST

UNE

MOTOCYCLETIE

A

USAGE RESTREINT

OONT

L'USAGE

N'EST

PAS

DESTINE AUX VOIES PUBLIOU

ES

.

4

MFD.

BYYAMl\HA

tv'OTOR

CO.

,

LTD.

MM/YY

fv1ADE

IN

JAPAN

RESTRICTED-USE

tv'OTORCYCI£

~

OOYMvW-WvOTffiCX\LTD.

MM

I

YY

FABROJE

AU

JAffi\J

11/0TU:YCLETTE

A

USAGE

RESTREM

5

6

*****************

This

spark

igni

t

ion

sysl

om

meo

ts

all

requir

emen

tsof

th

e

Canadian

Interference

Causing

Equipment

Regulations.

Ce

systeme

d'allumage par etincelle de vtihicule

respecte

toutes

les

exigences

du

Aeglement

sur

le

materiel

brouillcu

r

du

Canada.

AWARNING

This

un

itcontains high pressure nitrogen gas.

Mishandling can cause explosion.

•

Read

owner's

ma

n

ua

l for instructions.

•

Do

not incinerate, puncture

or

open.

AAVERTISSEMENT

Cette

unite

contient

de

l'azote

a

haute

pr

essio

n.

Une

mauvaise

manipulation

peut

entrai

ner

d'exp

i

osion.

•

Vo

ir

le

manuel

d'utilisa

t

eur

po

ur

le

s

in

s

tructions

.

•

Ne

pas

brOl

er

ni

perforer

ni

o

uvr

i

r.

4AA·22259·70

3PT·

2118&-11

1-2

7

A WARNING

•BEFORE

YOU

OPERATE THIS VEHICLE, READ

THE OWNER'S MANUAL

AND

ALL LABELS.

•NEVER CARRY A PASSENGER. You increase

your risk of losing control

if

you carry a passenger.

•NEVER OPERA

TE

THIS VEHI

CLE

ON

PUBLIC

ROADS. You can collide with another vehicle

if

yo

u operate this vehi

cle

on a public ro

ad

.

•AL

WAYS WEAR AN APPROVED MOTORCYCLE

HELMET, eye protection, and protective clothing.

•E

XPERIENCED RIDER ONLY.

5PA

-2

t 1

8K-OO

8

A

AVERTISSEMENT

•

LIRE

LE

MANU

EL

DU

PROPRIETAIRE

AINSI

QUE

TOUTES

LES

ETIOUETIES

AVANT

D'UTI

LI

SER

CEVE

HICULE.

•

NE

JAMAIS

TRANSPORTER

DE

PASSAG

ER.

La

condui

le

avec

passager augmente

les

risques de perte

de

con

l

r61e.

•

NE

JAMAIS

ROULER

SUR

DES

CH

EMI

NS

PUBLICS.

Yous

pourriez

entrerencollision

avec

un

a

Ulr

e

vehicule.

•

TOU

JO

URS

PORT

ER

UN

CASQUE

DE

MOTOCYC

LISTE

AP

P

ROUVE,

des

l

unetles

et

des

vetemen

ls

de

protection.

•

EXCLUSIVEMENT

POUR

L'USAGE

D'UN

CONDUC

TEUR

9

EXPERI

MENT

E.

5PA·2

11

BK·10

Lapr

ess

ion des

pne

us a

froid

doil n

orma

l

ement

et

re

reglee

comme

su

it.

AVAN

T:

100kP

a,

1.00kgf/cm2, 15psi

ARRIERE

: 1

OOkPa,

1

.OOk

f/

cm2

, 1S

psi

JRV-21668-

BO

10

~?i~vJ~

.e

normal pressure should be set as

FRONT: 100kPa, (

1.

00kgf/cm2}, 15psi

REAR : 100

kPa

, 1.00k f/cm2, 15

si

DESCRIPTION

EASIOX3010

DESCRIPTION

1 2 3 4 5 6 7 8

J

9

10

11

12

13

17 18 19

20

16

15

14

24 23 22

21

1.

Clutch lever 13. Headlight

2.

Engine stop switch 14. Radiator

3.

Multi-function display 15. Coolant drain bolt

4.

Main switch

5.

Start switch 16. Rear brake pedal

17. Valve joint

6.

Front

brake lever

7.

Throttle grip 18. Starter knob/idle adjusting screw

19. Air cleaner

8.

Fuel tank cap 20. Catch tank

9.

Taillight 21. Drive chain

10. Kickstarter crank 22. Shift pedal

11. Fuel tank 23. Oil dipstick

12. Radiator cap 24. Front fork

TIP~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~

• The machine you have purchased may differ slightly from those shown in the following.

• Designs and specifications are subject to change without notice.

1-3

EAS1DX3011

CONSUMER INFORMATION

There are two significant reasons for knowing

the serial number ofyour machine:

1.

When ordering parts, you can give the num-

berto your Yamaha dealerfor positive iden-

tification of the model you own.

2.

If yourmachine is stolen, the authorities will

need the numberto search for and identify

your machine.

EAS1DX3012

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number "1" is

stamped into the right side of the frame.

EASIDX3013

ENGINE SERIAL NUMBER

1-4

CONSUMER INFORMATION

EAS1DX3014

MODEL

LABEL

The model label "1" is affixed to the frame un-

derthe seat. This information will be needed to

order spare parts.

EAS1DX3015

VEHICLE EMISSION CONTROL INFORMA-

TION

LABEL

The Vehicle Emission Control Information label

"1

11

is affixed at the location in the illustration.

This label shows specifications related to ex-

haust emissions as required by federal law,

state law and Environment Canada.

[Al

rnJ

A:

For Canada

B:

For USA and Canada

FEATURES

EAS20170

FEATURES

EAS1DX3016

OUTLINE OF THE Fl SYSTEM

The

main

function

of

a

fuel

supply

system

is

to

provide

fuel

to

the

combustion chamber

at

the opti-

mum

air-fuel

ratio

in

accordance

with

the

engine

operating conditions

and

the

atmospheric tempera-

ture.

In

the

conventional carburetor

system,

the

air-fuel

ratio

of

th~

mixture that

is

supplied

to

the

combustion chamber

is

created

by

the volume of the

intake

air

and

the

fuel

that

is

metered

by

the jet

used

in

the

respective carburetor.

Despite

the

same

volume of intake

air,

the

fuel

volume requirement varies

by

the engine operating

conditions,

such

as

acceleration, deceleration,

or

operating underaheavy

load.

Carburetors that

me-

ter the

fuel

through

the

use

of

jets

have

been

provided

with

various auxiliary devices,

so

that

an

op-

timum

air-fuel

ratio

can

be

achieved to accommodate

the

constant changes

in

the operating

conditions

of

the

engine.

As

the

requirements for

the

engine

to

deliver

more

performance

and

cleaner exhaust

gases

increase,

it

becomes

necessary

to

control

the

air-fuel

ratio

in

a

more

precise

and

finely

tuned

manner.

To

ac-

commodate

this

need,

this

model

has··adopted

an

electronically controlled

fuel

injection (Fl)

system,

in

place

of

the.conventional carburetor

system.

This

system

can

achieve

an

optimum

air-fuel

ratio

required

by

the

engine

at

all

times

by

using amicroprocessorthat regulates

the

fu~

injection volume

according

to

the

engine operating conditions detected

by

various sensors.

The

adoption

of

the

Fl

system

has

resulted

in

ahighly precise

fuel

supply,

improved engine

response,

better

fuel

economy'

and

reduced

exhaust emissions.

1 2 3 4 5 6 7 8

11

10 9

1. Engine trouble warning light

2. Lean angle sensor

3. Fuel pump

4. Intake air pressure sensor

5. Fuel injector

6. Battery

7.

Intake air temperature sensor

8. ECU (engine control unit)

9. Throttle position sensor

1O.Coolant temperature sensor

11.Crankshaft position sensor

12.Ignition coil

13.Speed sensor

1-5

FEATURES

EAS1DX3017

Fl

SYSTEM

The fuel

pump

delivers fuel to

the

fuel

injectorvia the

fuel

filter.

The

pressure regulator maintains

the

fuel pressure that

is

applied

to

the

fuel

injector at a certain level. Accordingly,

when

the

energizing

signal

from

the

ECU

energizes the fuel injector, the

fuel

passage

opens,

causing the

fuel

to

be

inject-

ed

into

the

intake manifold only during

the

time the passage remains

open.

Therefore, the longer

the

length of

time

the

fuel

injector is energized (injection duration),

the

greater the volume

of

fuel

that

is

supplied. Conversely, the shorter

the

length

of time

the

fuel

injector

is

energized (injection duration),

the lesser

the

volume of

fuel

that is supplied.

The injection duration

and

the injection timing are 9ontrolled

by

the

ECU.

Signals that

are

input

from

the throttle position sensor, coolant temperature sensor, atmospheric pressure sensor,

lean

angle

sensor, crankshaft position sensor, intake air pressure sensor

and

intake airtemperature sensor

en-

able

the

ECU

to

determine the injection duration. The injection timing is

deterr:nined

through

the

sig-

nals

from

the crankshaft position sensor.

As

a result,

the

volume

of

fuel

that

is

required

by

the

engine

can

be

supplied at

all

times

in

accordance

with

the driving conditions.

10

9

1. Fuel pump

2.

Fuel injector

3.

ECU (engine control unit)

4.

Throttle position sensor

5.

Coolant temperature sensor

6.

Crankshaft position sensor

7. Intake air pressure sensor

8.

Throttle body

9.

Intake airtemperature sensor

1a.Air filter case

A.

Fuel system

B.

Intake system

C.

Control system

6

1-6

EAS10X3018

INCLUDED PARTS

EAS1DX3019

VALVE

JOINT

This valve joint

11

1

11

prevents fuel from flowing

out and is installed to the fuel tank breather

hose.

ECA1DX100t

t?l@§.§1~~~~~~~~~

In

this

installation, make sure the arrow fac-

es

the

fuel tank and also downward.

EAStDX3020

SPARK

PLUG WRENCH

This spark plug wrencti

11

1

11

is used to

r~move

and install the spark plug.

EASIOX3021

NIPPLE WRENCH

This nipple wrench

"1

11

is used to tighten the

spoke.

1

1-7

INCLUDED PARTS

EAS1DX3022

HANDLEBAR PROTECTOR

Install the handlebar protector

11

1

11

so that the

notch

11

a

11

face backward.

EAS10X3023

HOOK (FUEL TANK)

The hook tank

11

1

11

is used to support the fuel

tank during maintenance.

EAS10X3024

FUEL HOSE JOINT COVER

The fuel hose joint covers

11

1" are used to pre-

vent mud, dust, and otherforeign material from

entering the fuel pump when the fuel hose is

disconnected.

EASIOX3025

COUPLER FOR CONNECTING OPTIO

NAL

PART

This coupler "1" is used for connection to an op-

tional Power Tuner and so on.

EC

A

IO

X1002

NOTICEj

___________

_

When no optional parts, etc.

ar~

connected,

connectthe connection terminal to the orig-

in

al coupler.

Before removing the coupler, thoroughly

wipe off any mud or water stuck to it.

Part name Part number

GYTR Power Tuner 33D-H59CO-

VO-OO

The GYTR Power Tuner is optional.

1-8

IMPORTANT INFORMATION

EAS20180

IMPORTANT INFORMATION

EASIDX302S

PREPARATION FOR REMOVAL AND DIS-

ASSEMBLY

1. Before removal and disassembly, remove all

dirt, mud, dust and foreign material.

2.

Use only the proper tools and cleaning

equipment.

Refer to "SPECIAL TOOLS" on page 1-15.

3.

When disassembling, always keep mated

parts together. This includes gears, cylin-

ders,pistons and otherparts

th

at have been

"mated" through normal wear. Mated parts

mustalways be reused or replaced as an as-

sembly.

4.

During disassembly, clean all of the parts

and place them in trays

in

the order of disas-

sembl

y.

This will speed up assembly and al-

low for the correct installation of all parts.

5.

Keep a

ll

parts away from any source of

fi

re.

EASIDX3027

REPLACEMENT PARTS

Use only genuine Yamaha parts for a

ll

replace-

ments. Use oil and grease recommended by

Yamaha for a

ll

lubrication jobs. Other brands

may be similar

in

function and appearance, but

inferior

in

qua

li

ty.

EAS1DX302B

GASKETS, OIL SEALS AND

0-RINGS

1. When overhauling the engine, replace all

gaskets, seals and 0-rings. All gasket sur-

faces, oil seal lips and

0-rings

must be

cleaned.

2. During reassembly, properly oil all mating

parts and bearings and lubricate the oil seal

lips with grease.

4

1.

Oil

2. Lip

3.

Spring

4.

Grease

EAS1DX3029

LOCK

WASHERS/PLATES

AND

COTTER

PINS

After removal, replace all lock washers/plates

"1" and cotter pins. After the bolt

or

nut has

been tightened to specification, bend the lock

tabs along a flat of the bolt

or

nut.

1-9

IMPORTANT INFORMATION

EAS1DX3030

BEARINGS AND OIL SEALS

Install bearings "1" and oil seals "2" so that the

manufacturer marks or numbers are visible.

When installing oil seals, lubricate the oil seal

lips with a light coat of lithium-soap-based

grease. Oil bearings liberally when installing, if

appropriate.

ECA13300

?Alo_T:iat=ii

=~·~~~~~------------

Do

not

spinthebearing

with

compressedair

because

this

will

damage the bearing sur-

faces.

1

..

EASIDX3031

CIRCLIPS

Before reassembly, check all circlips carefully

and replace damaged or distorted circlips. Al-

ways replace piston pin clips after one use.

When installing a circlip "1", make sure the

sharp-edged corner "2" is positioned opposite

the thrust "3" that the circlip receives.

EAS1DX3032

BASIC SERVICE INFORMATION

EAS1DX3033

QUICK FASTENERS

Rivet

type

1.

Remove:

•Quick

fastener

TIP

_____________

_

To remove the quickfastener, push its pin with

a screwdriver, then pull the fastener out.

~

1--"

2.

Install:

• Quick fastener

TIP

_____________

_

To install the quickfastener, push its pin sothat

itprotrudes from the fastener head, then insert

the fastener into the part to be secured and

push the pin in with a screwdriver. Make sure

that the pin is flush with the fastener's head.

1IT

·~

ill

BASIC SERVICE INFORMATION

Screw type

1.

Remove:

• Quick fastener

--;

~

__

..,...,...

TIP

___

~---~-~----

TQ

remove the quickfastener, loosenthe screw

with a screwdriver, then pull the fastener out.

2. Install:

•Quick

fastener

TIP-------~---~-

To install the quickfastener, insertthe fastener

into the part to be secured and tighten the

screw.

1-10

EAS1DX3034

',

:~

-,

rn.~

[]]

ELECTRICAL SYSTEM

Electrical parts handling

ECA16600

lft!llB

_______

_

Never disconnect a battery lead while the

engine

is

running; otherwise, the electrical

components could be damaged.

ECA16751

~~~~~~~~~~-

When disconnectingthe battery leads from

the battery, be sure

to

disconnectthe nega-

tive battery lead first, then the positive bat-

tery lead.

If

the positive battery

l~a~

is

.

disconnected

first

and atool

or

s1m1lar

item

contacts the vehicle, a spark could be gen-

erated,

which

is

extremely

dangerous.

BASIC SERVICE INFORMATION

1-11

TIP~~~~~~~~~~~~~~~

If a battery lead is difficult to disconnect due to

rust on the battery terminal, remove the rust us-

ing hot water.

ECA16760

Blr~--~~~~~~~-

Be sure

to

connectthe battery leads

to

the

correct battery terminals. Reversing the

battery lead connections could damagethe

electrical components.

ECA16nt

.,,,~~~~~~~~~

When connecting the battery leads

to

the

battery, be sure

to

connect

the

positive bat-

tery lead first, then the negative battery

lead.

If

the negative battery lead is connect-

ed

first

and atool

or

Yamaha WR450FB 2012 Application guide

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