04 WR450 Starter Clutch problem

7 replies to this topic
  • kevin1209

Posted September 22, 2005 - 06:40 PM


It seems like the starter is a hot topic lately, but mine is a little different. I had a crack in my left crankcase cover. I took it off, repaired it, and put everything back together. Now my starter clutch will not engage the starter motor when I hit the button. The starter motor spline just spins freely. It looks like the starter clutch and the spline for the starter motor are not touching. It worked before I took it apart, and I think I reassembled it correctly (no extra parts). Anyone know what I've done wrong? I don't want to take it to Yamaha. They will just start replacing parts instead of fixing the problem. HELP!

  • kevin1209

Posted September 23, 2005 - 04:45 AM


By the way, does anyone know where to get a service manual for an 04 WR450? I can't find one online, Yamaha only carries the stock owner's manual.

  • clark4131

Posted September 23, 2005 - 06:14 AM


It may be spendy, but you'd be hard-pressed to find a better manual than the Yamaha. Look on eBay, some folks are offering them in PDF form for a bit less, but I don't know if the '04 version is out yet...SC

  • Chris_from_Oz

Posted September 23, 2005 - 06:19 AM


It may be spendy, but you'd be hard-pressed to find a better manual than the Yamaha.

Yep, the Yamaha manuals are pretty decent, and easy to follow. :banghead:

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  • kevin1209

Posted September 23, 2005 - 02:50 PM


Thanks. Still looking for help with my starter problem. I'm trying to download pics, but am having trouble getting them to post.

  • Indy_WR450

Posted September 23, 2005 - 03:10 PM


you have to find a server to host your pictures and then link them or insert them via link on this forum post. :banghead:
Your drive spline on the motor should egage with the torque limiter and then to an idler that engages to the starter clutch gear. :applause:

  • grayracer513

Posted September 23, 2005 - 03:47 PM


Absent a manual, try looking at The Yamaha Parts Page and look at the illustration for the starter clutch of an '04 WR.
See if the picture helps any.

  • Indy_WR450

Posted September 23, 2005 - 05:39 PM


Most likely the torque limiter is not engaged with the idler. Try reseating the gear and spin the idler gear with your finger to find a seating position. The limiter should engage and the cover should go on flush without using the bolts to press the torque limiter into position. :banghead:


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