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Yamaha WR 450 2004 Service Repair Manual
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🏷️ Basic Information Identification Make: Yamaha Model: WR450F Year: 2004 Codes Model Code Prefix: 5TJ 👋 Introduction Market Position Segment: High-performance off-road/motocross/enduro motorcycle. Target Audience: Motocross riders, enduro enthusiasts, off-road...
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🏷️ Basic Information
Identification
Make:
Yamaha
Model:
WR450F
Year:
2004
Codes
Model Code Prefix:
5TJ
👋 Introduction
Market Position
Segment:
High-performance off-road/motocross/enduro motorcycle.
Target Audience:
Motocross riders, enduro enthusiasts, off-road recreational riders, and motorcycle mechanics.
Competitive Analysis
Key Competitors:
KTM EXC series, Honda CRF-X series, Suzuki RM-Z/DR-Z series, Kawasaki KX-F/KLX series.
Key Features
Vehicle Emphasis:
Powerful 4-stroke engine, advanced suspension, lightweight chassis, competitive off-road performance.
Manual Value Proposition:
Provides detailed, accurate, and essential information for maintaining, troubleshooting, and repairing the Yamaha WR450F 2004 model, empowering owners and technicians.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service and Repair
Secondary Coverage:
Troubleshooting, Maintenance, Diagnostics
Page Count
Estimated Page Count:
300+
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full disassembly, assembly, inspection, and repair of all internal engine components (piston, rings, cylinder, crankshaft, connecting rod, valves, camshaft, etc.).
Fuel System:
Carburetor (Mikuni BSR-41) inspection, cleaning, adjustment, and overhaul; fuel tank, fuel line, and petcock service.
Ignition System:
CDI system, spark plug specifications, testing, and replacement.
Cooling System:
Radiator, hoses, water pump, thermostat inspection and service; coolant specifications and replacement procedures.
Exhaust System:
Muffler and header pipe inspection and replacement.
Transmission Drivetrain:
Clutch inspection, adjustment, and replacement; gearbox disassembly, assembly, inspection, and service; chain and sprockets maintenance.
Suspension Front:
USD (Upside-Down) forks (Kayaba 46mm) disassembly, inspection, oil change, seal replacement, and adjustment procedures; steering head bearing service.
Suspension Rear:
Monocross rear shock absorber service, linkage inspection, lubrication, and adjustment; rear shock absorber overhaul and re-gassing procedures.
Brakes Front:
Hydraulic disc brake system service, caliper inspection and overhaul, pad replacement, fluid bleeding, master cylinder service.
Brakes Rear:
Hydraulic disc brake system service, caliper inspection and overhaul, pad replacement, fluid bleeding, master cylinder service.
Wheels Tires:
Wheel bearing inspection and replacement, rim and spoke inspection, tire pressure recommendations.
Electrical System:
Lighting system, battery maintenance, wiring diagrams, component testing (ignition coil, stator, rectifier/regulator), troubleshooting electrical faults.
Frame Chassis:
Frame inspection, swingarm service, footpeg and stand maintenance.
Bodywork:
Fender, fuel tank, seat, and side panel removal and installation.
Procedures Included
Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain lubrication and adjustment, brake fluid replacement, coolant flush.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides.
Repair:
Detailed step-by-step instructions for component repair, replacement, and overhaul across all major systems.
Specifications:
Torque values for all critical fasteners, valve clearance specifications, fluid capacities, electrical component resistance values.
Special Tools:
Identification and usage of specialized tools required for specific repair or maintenance tasks.
Technical Depth
Depth:
Comprehensive; covers everything from basic rider maintenance to full engine rebuilds and complex electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Print Quality
Quality:
High-resolution, clear illustrations and text.
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Type:
4-stroke, DOHC, 5-valve
Configuration:
Single Cylinder
Displacement:
449cc
Bore X Stroke:
95.0 mm x 63.4 mm
Compression Ratio:
12.5:1
Performance
Estimated Horsepower:
Approx. 50-55 HP (at crankshaft, estimated)
Estimated Torque:
Approx. 32-35 lb-ft (at crankshaft, estimated)
Fuel System
Carburetor Model:
Mikuni BSR-41
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
2.7 US gal (10.2 L)
🔧 Transmission
Standard
Type:
Constant mesh 5-speed
Clutch Type:
Wet, multiple disc
Features
Gear Ratios:
Manual provides specific gear ratios for each speed.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
2,170 mm (85.4 in)
Width:
815 mm (32.1 in)
Height:
1,270 mm (50.0 in)
Wheelbase:
1,475 mm (58.1 in)
Ground Clearance:
380 mm (15.0 in)
Weights
Dry Weight:
114 kg (251.3 lbs)
Wet Weight:
Approx. 120 kg (265 lbs) (with fluids, estimated)
Seat Height:
990 mm (39.0 in)
🛡️ Safety Features
Ratings
Safety Class:
Off-road motorcycle (no formal crash ratings like passenger cars)
Active Features
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Suspension:
Advanced Kayaba suspension provides stability and control over varied terrain.
Passive Features
Chassis Design:
Durable frame and components designed for off-road abuse.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable for this off-road model.
Driver Assistance
Assistance Features:
None (designed for pure off-road performance, not road-legal with rider aids).
Connectivity
Connectivity Features:
None (basic electrical system).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 10-15 hours of riding or as specified in manual; use Yamaha Yamalube or equivalent.
Oil Filter Replacement:
Every 20-30 hours of riding or with every oil change.
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Spark Plug Inspection:
Every 10-15 hours of riding.
Chain Lubrication:
Every 5-10 hours of riding, or as needed.
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG, JASO MA certified (e.g., Yamalube 4T)
Engine Oil Capacity:
1.00 L (1.06 US qt) without filter change; 1.10 L (1.16 US qt) with filter change.
Coolant Type:
High-quality permanent type antifreeze coolant, mix ratio 50/50 with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Carburetor Jetting:
May require jetting adjustments based on altitude and temperature for optimal performance.
Clutch Wear:
Aggressive riding can lead to premature clutch wear, requiring periodic adjustment and replacement.
Suspension Seals:
Fork seal leaks can occur with hard impacts or age; regular inspection is recommended.
Radiator Performance:
Ensure radiator fins are clean and coolant is fresh for optimal cooling, especially under sustained load.
📚 Vehicle History
Brand Heritage
Yamaha Offroad Legacy:
Yamaha has a long and successful history in motocross and off-road racing, building a reputation for performance, durability, and innovation.
Model Evolution
Wr450F Lineage:
The WR450F is Yamaha's premier 4-stroke off-road machine, evolving from earlier YZ-F based platforms to offer enduro-specific features and performance.
Production
Manufacturing Location:
Japan (Primary)
Production Years:
The WR450F has been in continuous production since its introduction, with annual updates and refinements.
🏆 Awards & Recognition
Recognitions
Performance Acclaim:
Yamaha WR models are consistently recognized by the off-road community and media for their class-leading performance and reliability.
Ratings
Editorial Reviews:
The 2004 WR450F was praised for its potent engine and capable chassis, solidifying its position as a top contender in the open-class enduro segment.
Certifications
Emissions:
Designed for off-road use, meeting relevant off-road emissions standards of the time. Manual may contain specific details.