2003 WR450, Need help on dialing in this wart hog!
Posted May 20, 2004 - 03:54 PM
Posted May 20, 2004 - 05:19 PM
Posted May 20, 2004 - 05:48 PM
Posted May 20, 2004 - 06:26 PM
Posted May 21, 2004 - 06:09 AM
Posted May 21, 2004 - 12:13 PM
The parts needed:
04 Left Side Case Part # 5TJ-15411-10-00 @ $ 92.49
04 Torque Limiter Part # 5TJ-15560-00-00 @ $204.99
04 Torque Limiter Cover Part # 5TJ-1549B-00-00 @ $28.99
04 Thrust washers (need 2) Part# 90201-105A8-00 @ $ 7.98
Gasket for side cover Part # 5TJ-15451-00-00 @ $ 4.49
see detailed instructions with pics at: www.wr450.com
Posted May 21, 2004 - 02:21 PM
Maybe you will shear the flywheel key and then again maybe you won't. I have the very first 2003 WR 450f of all of the Thumpertalk brothers and I lost a fork seal, and that is the only problem. Other members have replaced the flywheel key as many as 3 times. It is kind of a crap shoot. Some of the bikes have had NO problems and others have been broke down more than they have been ridden. There seems to be no rhyme or reason as far as I know. As I have said mine is the first and I've gotten over 1800 miles on my bike, others have far more miles with no throubles and then there are guys like Jeff in Eugene who has had three keys shear and finally Yamaha replaced the crank and all related parts and I guess that his problems are solved as I haven't seen any more posts from him on the subject.(He had a lot less miles when it went the first time) I hope that this helps to answer the question.
Posted May 21, 2004 - 02:31 PM
Posted May 21, 2004 - 08:42 PM
Posted May 22, 2004 - 08:09 PM
How can you say it will break eventually? There are a lot more of these '03's out there that have had no problems than have. I personally have over 2600 miles with no problem at all. You claim to have ridden over 5000 miles before doing the "upgrade" with no problems. Most guys will never put 5000 miles on these bikes in 5 years. Throwing down $260 for a fix that has not been proven to be needed is a waste in my opinion.
Not trying to call you out but wanted to let it be known that it's not a death sentence to have not done this mod.
Watch, Mine will probably break now
Posted May 23, 2004 - 07:36 AM
As far as jetting goes, I would recommend buying the JD jetting kit through the TT store. It is well worth the $60.
Posted May 23, 2004 - 08:25 AM
Throwing down $260 for a fix that has not been proven to be needed is a waste in my opinion.
If a person has had the Yamaha TSB done on his bike then this upgrade is absolutely necessary, IMO. There have been instances where it doesn't break like it should (due to the flywheel being loctited to the crank from the TSB) and something else breaks instead (starter, starter gears, cases.) The starter update resolves this issue with the torque limiter that is the main part of the 04 upgrade.
I haven't had the TSB done on my bike and it lost a woodruff key at just over 2,600 miles. With as many miles as I put on in the back country, $260 is cheap peace of mind.
Yes, I still pack a flywheel puller, two spare woodruff keys (and all the tools necessary to fix it on the trail) in my fanny pack.
Posted May 23, 2004 - 09:47 AM
Posted May 23, 2004 - 11:13 AM
Posted May 23, 2004 - 11:40 AM
As far as the loctite goes was it the flywheel taper to the crankshaft taper that was being loctited or the nut on the flywheel? I can't see there being enough loctite left between the tapers to cause enough holding force to not shear in the case of a bad torque limeter. I wonder if the bikes that have broken in other areas have been caused by the TSB being performed incorrectly? I also know that the YZ 450's have had problems with the case breaking around the kickstarter. I wonder if Yamaha didn't throw this engine into production a little early.
Does the new torque limeter look like it warrants the high price they are wanting for it?
I guess $260 isn't too outrages for a little peace of mind. A freind of mine pulled his starter because he was worried about it. He did have some backfire/ stalling issues. He found a few teeth missing on the starter. I figured he had a bad torque limeter.
The dealer supposedly did the TSB on mine when I bought it but they didn't punch the frame.
I just have a hard time plopping down the $260 to fix something I have never had a problem with. (sounds like I'm trying to talk myself into it )
BTW Dave, I have a sprocket guard for you buddy with the YZ 250F.
Posted May 23, 2004 - 11:49 AM
Posted May 23, 2004 - 04:52 PM