Picked up a first bike, '03 WR450 plated, need some help figuring out what I have.

[jpgolf14]

Hi,

 

I just picked up my first bike a few weeks ago.  It is an '03 WR450 that has been plated by a previous owner.  I have put about 150mi of road and forest road on the bike and am having a blast so far.  I have a few questions trying to figure out what exactly is on this bike.  Newb questions as this is my first motorcycle.

 

For backround I have been tinkering with cars ('87 Camaro) for the last 15yrs.  I am confident it mechanical work and DC electrical.  I don't quite yet understand what is AC vs DC on the bike and how it affects what I would like to change on the bike.

 

I am also an avid mountain biker so I am excited to get this bike on some single track.

 

First of all the bike, went for a ride to Spada Lake in WA.

 

Now, first of all, some questions about the street legal kit on this bike.  Anyone know what I have here?  The headlight surround plastic looks similar to stock but it is missing the lower "chin".  Some more info.  There is an independent switch on the cental handle bar that allows me to turn off the headlight.  This seems pointless to me.  Any reason why I shouldn't just remove the switch and have the headlight on any time the key is on?  Also, the light swich by the left grip seems to only control the rear light.  Off leaves the tail light off all the time.  P and H seems to have identical functionality where the rear light is on when the key is on.  I would really like to tie the headlight and taillight to the key and remove some unnecessary switches.  Good idea or not?  The off/P/H selector is missing the decorative slider, anywhere I can get this?  The hi beam / low beam switch seems to do nothing.  The previous owner told me the headlight is setup for a high beam but he took it out because it drained the battery.  I would like to restore the hi beam.  All four turn signals seem to work properly.  The rear turn signals are built into the taillight. 

 

The brake light is only tied to the rear brake.  I would like to wire it so either the front or rear brake will trip the brake light.

 

I added a Trail Tech Vapor dash.  Speed and temp seem to work well but the tach is spotty.  What should the idle rpm be on this bike?

 

What is the size of the OEM fuel tank?  I seem to find conflicting info from 1.8 to 2.6 gallons.

 

The previous owner told me the exhaust is a GYTR.  He also gave me the restrictor (pipe organ?) that he removed from the muffler.  Exhaust is super loud, but I think I am ok with that.  Anything I should know?  The head pipe has 1 small and 1 medium sized dent.  Will this have any effect on performance?

 

I found that riding the bike on the road I had a stumble at constant throttle.  After doing some research, I unplugged the TPS and that seemed to solve the problem.  I also disconnected the gray wire.  I will shorten the throttle stop next.

 

Starting the bike is interesting.  It starts super easy with the kickstarter.  However I seem to have an issue with the electric starter.  About 1/3 to 1/2 the time the starter will not turn over the engine at all.  It is like the piston is in a certain position that the starter cannot overcome.  The other 2/3 to 1/2 time the bike fires up in less than a second.

 

When cruising and suddenly ripping the throttle I get a bit of a hesitation.  It sounds like that may be the calibration of the accelerator pump shot.  I will look at that soon.

 

The clutch and brake levers have ugly blue inserts and have quite a bit of up and down play.  The brake lever is a little crunchy.  I would like to swap these out.  It looks like the levers are pretty universal.  Anything I should know?  Looks like I would need a clutch lever with hot start mounting.

 

The grips on the bike are pretty well shot.  I attempted to replace them with ODI Rogue lock on.  I have these on my mountain bike and like them.  Left side went on with no issue.  However the throttle side had some issues.  The ODI throttle cam appears to be too narrow and the diameter is too large.  This is using throttle cam A.  The throttle would not return to idle quickly with this throttle cam.  Also, the grip had way too much side to side play.  My plan is to use the glue on ODI Rogue grip on the throttle side with the OEM throttle tube.

 

Can anyone tell me what the excess electrical capacity is like on this bike?  I would like to add a charger for my mobile phone.  I use the phone for navigation.  Would an extra 1.4amps be ok?  The Trail Tech Vapor has a 0.5amp fuse on it.

 

Mods the bike came with:

Street legal mods (key, turn signals, different tail light, ignition button)

GYTR exhaust (restrictor removed)

Devol frame and radiator guards

skid plate

 

Mods I have done:

Trail Tech Vapor

Gray wire

Unplugged TPS

Bark busters

grips

phone mount (gps)

 

I know that is a million questions.  But any information will help.  Thanks.

 

John

[jpgolf14]

 

 

[jpgolf14]

 

 

[jpgolf14]

 

 

[jpgolf14]

 

 

[jpgolf14]

I remember another question I have.  The bike came with some kind of speedometer.  It can be seen in the one picture above, below the Trail Tech Vapor.  The speedo is connected to what I believe is the stock cable drive at the front wheel.  I believe the speedo is not stock, I understand these bikes probably only came with an hour meter connected to the stock cable.  I would like to remove the speedo but I would need a way to plug the cable at the front hub.  Does anyone make a cap for this connection?  Also the speedo has two wires going to it.  I can only imagine these wires are for a back light, however if the speedo does have a backlight it is not working.   I just want to make sure this wiring is not stock before I remove it.

 

Thanks again.  I have already learned a ton from this website.

 

John

[ThumpMe]

LOTS of questions!

That is definitely an aftermarket light set up. My best guess is maybe Baja Design? I have picked up several different styles of handlebar switch combinations over the years, E-bay usually has several different styles always listed. Some have a few more or different locations of the various switches but all can be wired in to work with a little time and patience. Just depends on how many switches and how much wiring you want to get into.

Stock they came with just a re-setable (PIA) odometer which ran off a cable that came off the front wheel. They did make a replacement spacer for a while but probably non existant anymore. You can pull the cable off and put a plastic cap plug of the right size over where the cable used to screw on for a nice cover to seal it off.

I kind of like being able to shut off a headlight. Had a battery go tits up several years back on a DS ride but by turning off the headlight it would just get enough juice to be able to ride it. This was on another brand of scooter but showed me the value of being able to turn off a headlight.

Stock headlights come with a high and low H-4 bulb but to make them work you need to add another wire from the Hi/Low switch to the connector that plugs into the bulb. Since that looks like a DS kit it probably already is wired for that. He probably just disconnected it?

Stock '03's also only light up the lights when the motor running lights are AC everything else is DC, as the power to the headlight comes off the lighting coil. They are not connected into the battery as to small a battery to effectively run the lights. If they connected the lights straight into the battery that could explain why it kills the battery with high beam. That should be looked at, as well as probably the whole wiring job just so you know what you got going.

To add brake light to the front you either need to add a brake light switch (it can be done with a micro switch, or some people change the master cylinder out for one off a quad TRX Honda or Yamaha YFZ?) as those have brake light switches in them and also pump more fluid for better stopping power. I added one off a TRX on my old '99 when I DS'd it.

Tank (that looks like a stock one) is 2.6 gallons.

Head pipe can be fixed by taking off, filing with water and freezing it solid. Usually takes 4-5 freeze cycles placing the pipe into you freezer trying to place it so the water in the middle (which freezes up last) is positioned right where the dent is. This really works! Do a search on this site am sure it has been written up before.

If Trail Tech tach is not reading well, check the red wire that wraps around your spark plug wire. Needs to have several wraps around it to pick up the pulses correctly.

You might want to get a manual and use it to adjust the TPS. I did mine after I broke and repaired it and it made a noticeable difference in how the motor ran.

Throttle hesitation is probably jetting or possibly dirty carb. Did it sit parked for a while?

Loud pipes are bad. They loose us more riding ground then anything else, as well as piss off guys riding behind you! I like mine a little throaty but not to loud. Also look down it and if you do not see a screen it is NOT quipped with a spark arrestor. Important if riding on Forest Srv. as well as BLM lands.

I am sure it will have enough power to charge/run a phone. I run heated grips, LED headlight, radiator fan, and GPS with no problems.

Edited December 4, 2015 by ThumpMe

[jpgolf14]

ThumpMe,

 

Thank you very much for the info.  I know I have a lot of questions but your answers are very helpful.

 

The tail light is wired to DC.  At least that should draw much less power than the headlight.  The headlight does look like it is wired to AC.  It only turns on when the engine is running.  I will hook up the high beam and see what happens.

[DeepPurplishBlue]

That exhaust is the stock 03 WR450 setup.   It is terrible.   Heavy and restrictive even with the baffle out.   

And with the baffle out it can be obnoxiously loud and not adding the performance that the increased noise

would suggest...    There used to be a Promoto billet insert that you would put in after removing the baffle

to calm the noise down but I don't think it is available anymore.

 

Best bet would be to dump it for a YZ450F exhaust.   Usually cheap on ebay.   The YZ mufflers do not have

a USFS screen from the factory but if you need one for it they are readily available and usually cheap also.

[flyandride]

That mechanical speedometer under the Trail Tech looks like a universal speedo for Japanese bikes and is sold by JC Whitney and others.  I've used a couple of them on DS conversions and they work fine.  I kind of like the old school look anyway.  

[jpgolf14]

That exhaust is the stock 03 WR450 setup.   It is terrible.   Heavy and restrictive even with the baffle out.   

And with the baffle out it can be obnoxiously loud and not adding the performance that the increased noise

would suggest...    There used to be a Promoto billet insert that you would put in after removing the baffle

to calm the noise down but I don't think it is available anymore.

 

Best bet would be to dump it for a YZ450F exhaust.   Usually cheap on ebay.   The YZ mufflers do not have

a USFS screen from the factory but if you need one for it they are readily available and usually cheap also.

Thanks for the info.  I will keep that in mind.  The exhaust is stupid loud. 

[jpgolf14]

That mechanical speedometer under the Trail Tech looks like a universal speedo for Japanese bikes and is sold by JC Whitney and others.  I've used a couple of them on DS conversions and they work fine.  I kind of like the old school look anyway.  

Gotcha.  My issue with the speedo is that it does not light up.  I suspect it is supposed to, there are two wires going to it, but it doesn't seem to work anymore.  Anyway I am pretty happy with the Trail Tech.  Other than the tach is all over the place, I will need to fiddle with the tach pickup.

[ThumpMe]

On your tach pickup.

 

I believe you also need to make sure that red wire wrapped around the spark plug lead from the Trail Tech  is not real close to the spark plug end as that can cause all sorts of weird stuff to happen. 

[jpgolf14]

On your tach pickup.

 

I believe you also need to make sure that red wire wrapped around the spark plug lead from the Trail Tech  is not real close to the spark plug end as that can cause all sorts of weird stuff to happen. 

 

That is interesting.  The instructions that came with the Trail Tech said it needs to be wrapped around the coil, underneath the weather seal that seals the top of the head.  That is how I have mine setup now.  It is kind of clunky.  I emailed Trail Tech and they said I could wrap the wire around the coil lead.  I will try that next.

[ThumpMe]

That is interesting.  The instructions that came with the Trail Tech said it needs to be wrapped around the coil, underneath the weather seal that seals the top of the head.  That is how I have mine setup now.  It is kind of clunky.  I emailed Trail Tech and they said I could wrap the wire around the coil lead.  I will try that next.

 

 I put the Trail Tech on my '99 probably 5-6 years back. Maybe they changed the instructions? I have mine wrapped around the spark plug lead near the back of the gas tank about midway between the coil mounted up by the carb and the cap for the spark plug. That is where my instructions said to place it, It works great. 

[jpgolf14]

 I put the Trail Tech on my '99 probably 5-6 years back. Maybe they changed the instructions? I have mine wrapped around the spark plug lead near the back of the gas tank about midway between the coil mounted up by the carb and the cap for the spark plug. That is where my instructions said to place it, It works great. 

 

I will give that a shot.

[ftl900]

For the front brake switch, you can buy a pressure switch that goes on your front brake line, near the master cylinder.  

$15 or so amazon, ebay, and cheaper (about $6) from china. Just make sure it's for a Yamaha so the threads fit right.

http://www.ebay.com/itm/Tusk-Hydraulic-Brake-Switch-for-Nissin-Honda-Yamaha-Kawasaki-Suzuki-Motorcycle-/271422223873?hash=item3f32067601:g:jxsAAOSw3ydVp77a&vxp=mtr

 

 

 

Here's your headlight.. says it's an OEM 2005 450 model, but I haven't seen one like that before.

http://www.ebay.com/itm/Yamaha-Wr450F-DOT-Street-Legal-Headlight-Enduro-/291637738397?hash=item43e6f6bb9d:g:NJ8AAOSw-vlVpbuL&vxp=mtr

 

Edited December 18, 2015 by ftl900