WR450f 2003 starter upgrade problem
Posted December 08, 2010 - 12:22 AM
Greetings from Poland I've read posts from the archive and I found that to do a starter upgrade mod I need:
5TJ-15560-00-00 - no1. on this image http://www.boats.net...UTCH/parts.html I have bought used one from quad yfz450 2005 (new costs 440$ at Yamaha Poland!)
5TJ-1549B-00-00 - Yamaha wants ~50$ for it here in Poland so I will try to find used or aluminium tuning cover (have you seen a shop with it - shipping to Poland?)
90201-105A8-00 - the same are with the old starter so I've got it
90380-10002-00 - bushes (one or two? where I should install it?)
The wr450.com does not exist anymore so I can't find how to do a mod.
Posted December 08, 2010 - 08:54 AM
The washers go on both sides of the new clutch thingie. As far as the cover, you definitely need the more bulbous one.
Total time to do the mod is 15 minutes.
Posted December 08, 2010 - 11:34 PM
Can I (after doing this mod) start cold engine by e-start or is it risky?
So happy that I will have magic button
Posted December 09, 2010 - 11:08 PM
Posted December 10, 2010 - 09:25 AM
Posted December 10, 2010 - 05:49 PM
The parts required to do the modification are the Damper Assembly, part number 5TJ-15560-00-00; Cover Assembly 2, part number 5TJ-1549B-00-00; O-ring, part number 93210-58346-00; Washer Plate, part number 90201-105A8-00 (2 each) and Bushing, part number 90380-10002-00 all from a 2004 WR450F.
You are going to replace parts that are on your 2003 WR450F. Remove and throw away Gear Idler 1, part number 5TJ-15512-00-00; Cover 2, part number 5TJ-15423-00-00 and O-ring, part number 93210-57428-00.
To incorporate the modification do the following:
1. Remove the 2003 WR450F parts listed above from your motorcycle.
2. Install the new 2004 WR450f parts listed above on to your
motorcycle as follows:
a. Install the new Bushing by gently tapping the Bushing into
the hole in Crank Case 1 where you removed Idler Gear 1.
b. Place one of the Washers Plate on each side of the
c. Install the Damper Assembly into the Bushing in Crank Case 1
while meshing the gear teeth into Gear Idler 2.
d. Install the O-ring on Cover Assembly 2.
e. Install Cover Assembly 2 on Crank Case 1.
You can not complete the modification if you do not have the Bushing, part number 90380-10002-00. This is because the shaft that the new Damper Assembly, part number 5TJ-15560-00-00 spins on is smaller in diameter than the shaft on Gear Idler 1, part number 5TJ-15512-00-00. You install the Bushing, part number 90380-10002-00 into Crank Case 1 to provide a tight fit for the 2004 Damper Assembly.
You say, "starter idler gear from quad yfz doesn't fit maybe some one got the right one to wr?"
Have you used a part name incorrectly? You do not change the original Gear Idler 2 on the motorcycle. The Damper Assembly is the important part and it replaces Gear Idler 1 on your 2003 motorcycle. The part numbers for the 2005 YZF450 quad and the 2004 WR50F motorcycle show that they use the same Damper Assembly. Ignor the first three characters in the part number
(5TG 5TJ) they indicate the model and year. The rest of the part number is the important part 15560-00-00.
Posted December 11, 2010 - 02:29 AM
It's Damper Assembly 5TG-15560-00-00 (yfz450 2005)
I don't have a bushing yet so I can be wrong but not also the shaft is different, also the quanity of inside sprocket teeth of Damper Assembly is greater then in old 5TJ-15512-00-00 or 5TJ-15560-00-00 so I think they not be working with Gear Idler 2 in my WR (the gear idler 2 and so the case in quad yfz are different
Posted December 11, 2010 - 09:14 AM
Posted December 11, 2010 - 09:57 AM
Does Anyone wants some parts to quad yfz?