2006 Yamaha WR450F(W) Owner's Service Manual (P/N 5TJ-28199-44)

Yamaha’s WR450F(W) Owner’s Service Manual, publication 5TJ-28199-44, first edition August 2006, covers operation, maintenance, tuning, and repair. Regional designations are WR450FW for the USA, Canada, Australia, and New Zealand, and WR450F for Europe and South Africa, with model codes 5TJE, 5TJF, and 5TJG.

• Engine repair: Engine removal, crankcase separation, cylinder-head and valve service, camshaft installation, piston inspection, crankshaft checks, and balancer service.

• Clutch and transmission: Clutch disassembly and inspection, kick axle and shift shaft service, and removal and inspection of transmission gears, shift cam, and shift forks.

• Fuel and cooling: Keihin FCR MX39 carburetor disassembly, accelerator-pump timing adjustment, air induction system inspection, radiator checks, and water-pump service.

• Brakes and chassis: Front and rear brake repair, hydraulic bleeding, front fork oil-seal replacement, steering-head service, swingarm inspection, and rear suspension linkage work.

• Electrical diagnosis: Ignition, electric starting, charging, lighting, and signaling checks, including the AC magneto, starter clutch, starter motor, and throttle position sensor.

• Reference diagrams and tuning: Lubrication diagrams, cable routing diagrams, valve-pad selection tables, a multi-function display function diagram, wiring diagrams, sectional views, and suspension-setting charts.

The manual introduces owners to operation and basic maintenance, while its internal repair procedures are suited to mechanics with the measuring equipment and special tools identified for each job.

Identification, Operation, and Routine Maintenance

The identification section locates the VIN on the steering head, the engine serial number on the right side of the engine, and the model label beneath the seat. Regional model codes help match the machine to the applicable specifications before parts are ordered.

General information covers controls, the multi-function display, starting, break-in, cleaning, and storage. Maintenance schedules and pre-operation checks accompany procedures for air-filter care, oil and coolant changes, drive-chain adjustment, and valve-clearance inspection.

Engine and Drivetrain Repair

The engine chapter provides disassembly, inspection, and assembly procedures rather than repair overviews alone. Exploded views and job instruction charts identify components and the extent of removal for each operation.

Valve-pad selection tables connect measured clearance and installed pad thickness to replacement-pad selection. This helps distinguish a clearance adjustment from work requiring further valve-train inspection.

The dry-sump lubrication system has dedicated oil-pump and oil-passage coverage. Clutch and 5-speed constant-mesh transmission sections add component wear checks and assembly orientation details.

Camshaft service includes a specific damage warning: uneven camshaft-cap fastener handling can damage the cylinder head, caps, and camshafts.

Carburetor Service and Tuning

The Keihin section covers jets, the throttle valve, accelerator pump, and hot-start components. Tuning charts explain how throttle opening, atmospheric conditions, jet selection, and needle position affect mixture.

The electrical chapter adds TPS resistance checks and output adjustment. Its connector-handling cautions address loss of waterproofing and electrical-component damage during testing.

Suspension, Steering, and Brakes

Front fork procedures include damper-rod work and seal installation, with special tools such as fork seal driver YM-A0948/90890-01502. Suspension-setting charts relate handling symptoms to damping, spring, and oil-level considerations; regional specifications distinguish applicable settings.

Brake coverage extends to master cylinders, calipers, seals, hoses, and bleeding. Steering and swingarm sections include bearing inspection and installation.

Rear shock coverage includes removal, spring adjustment, and mounting-bearing work; it does not authorize opening the nitrogen-filled cylinder or reservoir. Fuel handling and the pressurized rear shock require the precautions described in their respective sections.

Electrical Fault Finding

Ignition and charging flowcharts organize checks around symptoms such as no spark or a battery that will not charge. They help separate wiring and connection faults from component faults before replacement decisions are made.

Starter-circuit cut-off operation, relay and diode checks, starter-motor inspection, and speed-sensor testing supplement the main wiring diagram. The diagram distinguishes USA and non-USA connections.

A Preview of Jetting and Engine Inspection Data

These examples represent a small selection of the manual’s tuning and inspection specifications.

The carburetor data lists a standard #162 main jet and #45 pilot jet. Cooling-system capacity, including all routes, is 1.0 L (1.06 US qt).

The cylinder-head warp limit is 0.05 mm (0.002 in). Crankshaft inspection distinguishes a standard runout figure of 0.03 mm (0.0012 in) from the 0.05 mm (0.002 in) service limit.

Searchable Text, Bookmarks, and PDF Layout

Search and diagram detail: The PDF has searchable text and embedded bookmarks for all four languages. Some higher-level bookmarks lead to contents pages, while section bookmarks provide more direct navigation. Small wiring-diagram labels require zooming; the checked dense areas remain readable when enlarged.

The download contains one printable, 794-page PDF with English, French, German, and Spanish text. The total includes the front and rear covers and two blank pages near the end; these are not additional pages beyond the stated total.