2020 Yamaha WR450F WR450FL Owner’s Service Manual B7R-28199-71

Description

2020 Yamaha WR450F WR450FL Owner’s Service Manual — B7R-28199-71

This is the full 2020 Yamaha WR450F WR450FL Owner’s Service Manual, issued under part number B7R-28199-71 (also printed as B7R-28199-71-E0) and written for the WR450F and WR450FL enduro machines in their B7R6, B7R8 and B7R9 regional variants. It is the document that ships with the bike — a 410-page bilingual English/French servicing reference that runs from the pre-ride inspection list right through to crankcase splitting and transmission reassembly. First edition, June 2019. Delivered instantly as a PDF.

File Details

• Manual type: Owner’s Service Manual (English and French)
• Brand: Yamaha
• Models: WR450F, WR450FL
• Model codes: B7R6 (AUS, NZL, ZAF), B7R8 (CAN), B7R9 (AUT, BEL, CHE, CYP, CZE, DEU, DNK, ESP, FIN, FRA, GBR, GRC, HRV, HUN, IRL, ITA, NLD, NOR, POL, PRT, SVK, SVN, SWE, TUR)
• Document number: B7R-28199-71 / B7R-28199-71-E0
• Edition: First edition, June 2019
• Model year: 2020
• Page count: 410
• File format: PDF

IMAGES PREVIEW

Chapters Covered

• General Information — safety information, important labels, vehicle identification number and engine serial number, included parts (nipple wrench, handlebar protector, fuel hose joint cover, Power Tuner, optional coupler), preparation for removal and disassembly, replacement parts, gaskets/oil seals/O-rings, lock washers and cotter pins, bearings and oil seals, circlips, electrical system handling, special tools
• Specifications — general specifications, engine specifications, chassis specifications, electrical specifications, general tightening torques, engine tightening torques, chassis tightening torques
• Periodic Maintenance — periodic maintenance chart for the emission control system, general maintenance and lubrication chart, maintenance intervals for competition use, pre-operation inspection and maintenance, valve clearance adjustment, valve clearance shim chart, engine idling speed, throttle grip, spark plug, engine oil level and change, clutch lever free play, air filter element, throttle body joint, fuel line, cylinder head breather hose, exhaust system and spark arrester, coolant level and change, front and rear disc brake adjustment, brake fluid level, brake pads, brake hoses, brake bleeding, drive chain slack and lubrication, steering head, front fork legs, rear shock absorber assembly, swingarm, tires, spokes, wheels, wheel bearings, chassis fasteners, cables, brake and clutch lever lubrication, pedal and sidestand, battery, fuses, ignition timing, headlight bulb
• Chassis — front wheel (removal, disassembly, inspection, assembly, installation), rear wheel, front brake (caliper, master cylinder, brake pads, disc, bleeding), rear brake, handlebar (removal and installation), front fork (removal, disassembly, inspection, assembly, installation), steering head, rear shock absorber assembly, swingarm, chain drive (drive chain and sprockets)
• Engine — lubrication system chart and diagrams, engine removal and installation, exhaust pipe and muffler installation, camshaft (removal, inspection, timing chain, tensioners, decompression system, installation), cylinder head, valves and valve springs (lapping, seat inspection, guide replacement), cylinder and piston, generator, starter clutch, electric starter, clutch, shift shaft, oil pump, crankcase, crankshaft and balancer shaft, transmission
• Cooling System — cooling system diagrams, radiator inspection and installation, water pump disassembly, inspection and assembly
• Fuel System — fuel tank removal and installation, fuel pump removal, body and operation checks, injector, throttle body, fuel pressure check, throttle position sensor adjustment
• Electrical System — ignition system, electric starting system (starting circuit cut-off operation), charging system, signaling system, lighting system, cooling system circuit, fuel injection system (ECU self-diagnostic function, Yamaha diagnostic tool, fault codes), fuel pump system, electrical components, switches, bulbs and sockets, fuses, battery checking and charging, relays, diode unit, ignition spark gap, spark plug cap, ignition coil, crankshaft position sensor, lean angle sensor, starter motor operation, stator coil, rectifier/regulator, speed sensor, fuel sender, resistor, radiator fan motor, coolant temperature sensor, throttle position sensor input voltage, intake air temperature sensor, gear position switch, injector
• Troubleshooting — engine troubleshooting without fault codes, clutch, transmission, cooling system, brake, suspension, steering and handling, charging system, lighting system, signaling system, self-diagnostic function and diagnostic code tables
• Tuning — selection of the secondary reduction ratio (sprocket), drive and rear wheel sprocket setting parts, tire pressure, front fork setting, fork oil amount and characteristics, front fork setting parts, rear suspension setting, set length, rear shock absorber setting parts, suspension setting charts for front fork and rear shock absorber
• Wiring Diagram — full WR450F/WR450FL wiring schematic with numbered component list and complete colour code key

What This Owner’s Service Manual Gives You

The WR450F and WR450FL are competition enduro machines, and Yamaha wrote this manual around that reality. Maintenance is scheduled by race count as well as by mileage — every race, every third race, every fifth race — and the intervals cover items a trail-bike manual would never list: spark arrester cleaning, damper assembly bleeding, fork oil replacement, drive chain 15-link wear measurement, valve seat contact width, crank assembly width, transmission gear dog inspection. That level of detail is what separates this book from a generic repair guide.

Every procedure carries the tightening torque, service limit or clearance that goes with it — camshaft cap clearance (0.028–0.062 mm intake / 0.042–0.076 mm exhaust), valve clearance cold (0.10–0.17 mm intake / 0.15–0.22 mm exhaust), cylinder bore wear limit (97.060 mm), piston-to-cylinder clearance, 15-link drive chain length limit (239.3 mm), crank assembly width (61.93–62.00 mm). Wiring is documented down to individual conductor colours — grey and black/blue for the crankshaft position sensor, green/white and black/blue for the coolant temperature sensor, and so on — so fault tracing is done against the schematic rather than by guesswork.

The fuel injection system gets its own full chapter. The ECU self-diagnostic function is explained, every fault code from 12 (crankshaft position sensor) through 70 (engine forcibly stopped after prolonged idle) has a diagnostic table, and the Yamaha diagnostic tool connection procedure is documented. Fault code 12 and the crankshaft position sensor resistance (228–342 Ω), coolant temperature sensor at 20 °C (2513–2777 Ω) and intake air temperature sensor at 0 °C (5400–6600 Ω) are all printed where a technician can find them.

Coverage Highlights

• Full engine teardown: camshaft, cylinder head, valves, cylinder, piston, generator, starter clutch, clutch, shift shaft, oil pump, crankcase, crankshaft and balancer, transmission
• Complete chassis servicing: wheels, disc brakes, handlebar, front fork (with damper assembly bleeding and oil level measurement), steering head, rear shock, swingarm, chain drive
• Fuel injection diagnostics with fault code tables and ECU self-diagnostic procedure
• Electrical system testing for every sensor, relay, switch, coil and fuse on the machine
• Full colour-coded wiring diagram at the back
• Competition-use maintenance intervals, not just road-going schedules

Get Instant Access

Buying the 2020 Yamaha WR450F WR450FL Owner’s Service Manual gives you the entire factory servicing reference in one PDF — every torque figure, every service limit, every disassembly sequence, every fault code, and the full wiring schematic. It covers jobs from a pre-ride safety check to a complete engine overhaul, and it lets a competent home mechanic do the work correctly instead of tightening to feel and guessing at clearances. Download is instant after payment, the file works on any phone, tablet, laptop or desktop, and every page can be printed for the garage bench. No shipping, no waiting, no separate supplement to hunt down.