2003 WR450F technical help


19 replies to this topic
  • SEDUCE

Posted February 29, 2012 - 05:07 AM

#1

Hey guys first time post here

I have a 2003 model WR450F and the kick starter shaft has broken and snapped the right hand engine case and taken the top left bolt out of the inner engine case :bonk:

My question is should i get it tig welded as it is cast aluminium or just Devcon it in place?

Also has anyone ever done this as it looks as though u can only fit 2003 model kick start shaft assembly to it as 04 is different part number?

Anyone have one that want to sell or any of these parts?

Cheers guys

  • 2grimjim

Posted February 29, 2012 - 09:13 AM

#2

In 2004 Yamaha increased the kickstarter shaft size from 18mm to 20mm. The parts that were changed were the kickstarter, the kickstarter shaft assembly, and the clutch cover. Since these parts are unique to the 2003 WR and WR's from '04-'06 are all the same you could probably pick up all of the parts on eBay for fairly cheap.

I would use a threaded insert to repair the damaged bolt hole and toss the outer engine case (clutch cover?) and replace with the '04-'06 parts.

  • SEDUCE

Posted February 29, 2012 - 05:18 PM

#3

In 2004 Yamaha increased the kickstarter shaft size from 18mm to 20mm. The parts that were changed were the kickstarter, the kickstarter shaft assembly, and the clutch cover. Since these parts are unique to the 2003 WR and WR's from '04-'06 are all the same you could probably pick up all of the parts on eBay for fairly cheap.

I would use a threaded insert to repair the damaged bolt hole and toss the outer engine case (clutch cover?) and replace with the '04-'06 parts.


Oh really so you can use 04-06 parts but only if i change the kick starter shaft, kick starter and outer engine case is this correct as i asked Yamaha direct and they said no i can only use 2003 model stuff?

Anyone able to tell me definatly as i am about to buy the 2003 stuff brand new as i got told i can only use that model?

I would much rather have a 2004 model stuff if it is thicker as i have read this was a common problem?

  • 2grimjim

Posted February 29, 2012 - 05:26 PM

#4

i asked Yamaha direct and they said no i can only use 2003 model stuff?


Your Yamaha dealer has his head up his arse! Get the '04 parts. I am using them on my 2003. That's how I know how they fit.

One other thing you can do is use the clutch cover from a 2007-2009 YFZ450(4 wheeler). It has an oil jet that cools the bottom of the piston like the '07+ WR's and it bolts right on. Got one of those on my '03 WR too.

Let me know if you need part numbers.

  • SEDUCE

Posted February 29, 2012 - 05:52 PM

#5

Your Yamaha dealer has his head up his arse! Get the '04 parts. I am using them on my 2003. That's how I know how they fit.

One other thing you can do is use the clutch cover from a 2007-2009 YFZ450(4 wheeler). It has an oil jet that cools the bottom of the piston like the '07+ WR's and it bolts right on. Got one of those on my '03 WR too.

Let me know if you need part numbers.

Thanks mate for your help i really appreciate it as i know Yamaha are cocks some time. They tried telling me they have never heard of this before and i said well i googled it and there is hundereds of them it has happend to.

yeah if you could give me all the parts and part numbers i need it would be greatly appreciated as i said i dont want to go buy the 2003 model stuff incase it happens again.

Again thanks heaps buddy glad to talk to someone that knows

  • 2grimjim

Posted February 29, 2012 - 06:13 PM

#6

Thanks mate for your help i really appreciate it as i know Yamaha are cocks some time. They tried telling me they have never heard of this before and i said well i googled it and there is hundereds of them it has happend to.

yeah if you could give me all the parts and part numbers i need it would be greatly appreciated as i said i dont want to go buy the 2003 model stuff incase it happens again.

Again thanks heaps buddy glad to talk to someone that knows


Okay, here's all the part numbers. Might want to see if you can find some of the parts used. Prices from the dealer might a bit steep. The part number for the clutch cover is for the YFZ piece. I don't think the cost difference is much from the '04-'06 WR but it is an upgrade. Make sure to install the oil jet in the cover or you wont have any oil pressure.


Clutch cover parts ('07-'09 YFZ450);
Cover, 5D3-15431-00-00 (YFZ cover)
Nozzle, 5D3-15155-00-00 (oil jet for YFZ cover)
O-ring, 93210-05098 (O-ring for oil jet)
Gasket, 5TG-15462-02-00 (YFZ gasket. Has clearance cut for oil jet)
Check ball seat, 583-13113-00-00
Oil seal, 93101-14164
Gasket, 5TA-15453-00-00

Water pump parts ('03-'06 WR450);
Shaft, 5GR-12458-00-00
Oil seal, 93109-11073
Oil seal, 93102-12321-00
Bearing, 93306-00105

Kickstarter parts ('04-'06 WR450);
Kickstart assembly, 5XD-15601-10-00
Oil seal, 93102-20108-00
Kick boss, 5XD-15621-00-00

Some of these parts may superceed to a newer part number when the dealer orders them, but they should be the same part. Do double check the numbers when you order. I have fat, old fingers.

  • SEDUCE

Posted March 01, 2012 - 01:56 AM

#7

Okay, here's all the part numbers. Might want to see if you can find some of the parts used. Prices from the dealer might a bit steep. The part number for the clutch cover is for the YFZ piece. I don't think the cost difference is much from the '04-'06 WR but it is an upgrade. Make sure to install the oil jet in the cover or you wont have any oil pressure.


Clutch cover parts ('07-'09 YFZ450);
Cover, 5D3-15431-00-00 (YFZ cover)
Nozzle, 5D3-15155-00-00 (oil jet for YFZ cover)
O-ring, 93210-05098 (O-ring for oil jet)
Gasket, 5TG-15462-02-00 (YFZ gasket. Has clearance cut for oil jet)
Check ball seat, 583-13113-00-00
Oil seal, 93101-14164
Gasket, 5TA-15453-00-00

Water pump parts ('03-'06 WR450);
Shaft, 5GR-12458-00-00
Oil seal, 93109-11073
Oil seal, 93102-12321-00
Bearing, 93306-00105

Kickstarter parts ('04-'06 WR450);
Kickstart assembly, 5XD-15601-10-00
Oil seal, 93102-20108-00
Kick boss, 5XD-15621-00-00

Some of these parts may superceed to a newer part number when the dealer orders them, but they should be the same part. Do double check the numbers when you order. I have fat, old fingers.


THANK YOU so much mate you are a genious.

I will use my old water pump shaft to save me $30 :lol:

How hard and what else is needed to hook up the nozzle?

You are the best mate u have made my day and week.
I was worried that if i got the 03 model one it would snap again :bonk:

Oh will i also need a new kick starter lever as the shaft will be bigger correct or is it just inside the case its bigger?

Edited by SEDUCE, March 01, 2012 - 06:51 AM.


  • 2grimjim

Posted March 01, 2012 - 08:34 AM

#8

I will use my old water pump shaft to save me $30 :bonk:

How hard and what else is needed to hook up the nozzle?

Oh will i also need a new kick starter lever as the shaft will be bigger correct or is it just inside the case its bigger?


Check you old water pump shaft closely. If there is any groove worn into it from th seal it should be replaced.

The nozzle just plugs into the inside if the clutch cover (above the water pump). Don't for get to put the o-ring on first. When the new clutch cover is installed, the oil jet sticks through an existing hole in the inside case. When everything is bolted up, the jet is captured between the cases and cant go anywhere.

You dont need to replace the kick lever, just the knuckle that slides on the K/S shaft. The old kick lever will fit on the new knuckle (Kick boss, 5XD-15621-00-00). You cas replace the complete kicker assembly if yours is worn out. Just use the '04 part.

PM me if you need help.

  • SEDUCE

Posted March 01, 2012 - 03:58 PM

#9

Check you old water pump shaft closely. If there is any groove worn into it from th seal it should be replaced.

The nozzle just plugs into the inside if the clutch cover (above the water pump). Don't for get to put the o-ring on first. When the new clutch cover is installed, the oil jet sticks through an existing hole in the inside case. When everything is bolted up, the jet is captured between the cases and cant go anywhere.

You dont need to replace the kick lever, just the knuckle that slides on the K/S shaft. The old kick lever will fit on the new knuckle (Kick boss, 5XD-15621-00-00). You cas replace the complete kicker assembly if yours is worn out. Just use the '04 part.

PM me if you need help.


Sweet as mate, should be all good just will pay attention to the nozzel rest is mainly straight forward.
IF i do have a problem i will let u know or need help.

Thanks again mate

  • SEDUCE

Posted March 02, 2012 - 04:02 AM

#10

Ha well i hope u are right just cost me $526 in parts
got all the ones u said plus water pump gasket and the little o ring for the water pipe from the right radiator hose that goes into the pump.

Cheers again mate

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  • SEDUCE

Posted March 02, 2012 - 02:50 PM

#11

:bonk: got email today saying 14 week wait on the cover as there is nill stock and it is backorder :lol: not happy i want my bike to run

  • 2grimjim

Posted March 02, 2012 - 03:34 PM

#12

:bonk: got email today saying 14 week wait on the cover as there is nill stock and it is backorder :lol: not happy i want my bike to run


You can try eBay. Otherwise the '04-'06 WR cover will work too. Let me check with the Yammie dealer my wife works at to see if there are any in the US.

  • SEDUCE

Posted March 02, 2012 - 11:51 PM

#13

You can try eBay. Otherwise the '04-'06 WR cover will work too. Let me check with the Yammie dealer my wife works at to see if there are any in the US.

Cheers mate,
But will i still be able to run the oil suirter if i use the WR one as i have placed a order but its on hold till i find out what to do about a cover :bonk:

  • 2grimjim

Posted March 03, 2012 - 07:48 AM

#14

Cheers mate,
But will i still be able to run the oil suirter if i use the WR one as i have placed a order but its on hold till i find out what to do about a cover :bonk:


No, The WR cover doesn't have the oil jet, so if you have your heart set on the oil-jet side cover (from the YFZ), you'll have to wait. Give me to the end of the day here to check and see if Yamaha USA has the cover in country.

  • SEDUCE

Posted March 03, 2012 - 07:15 PM

#15

No, The WR cover doesn't have the oil jet, so if you have your heart set on the oil-jet side cover (from the YFZ), you'll have to wait. Give me to the end of the day here to check and see if Yamaha USA has the cover in country.

Does the oil nozzle make much or any difference?

  • 2grimjim

Posted March 03, 2012 - 07:43 PM

#16

Does the oil nozzle make much or any difference?


Depends on how hard the bike is run. If you plan to do a lot of riding with a handfull of throttle (long open streaches/highway), I'd say it's a good investment. Every other bike and ATV (even DRZ400's have had them since 2000) are using oil jets to keep the piston/pin cooled and lubed. Why Yamaha didn't incorporate one on the YZ's and WR's from the beginning I dont know.

  • SEDUCE

Posted March 04, 2012 - 12:40 AM

#17

Depends on how hard the bike is run. If you plan to do a lot of riding with a handfull of throttle (long open streaches/highway), I'd say it's a good investment. Every other bike and ATV (even DRZ400's have had them since 2000) are using oil jets to keep the piston/pin cooled and lubed. Why Yamaha didn't incorporate one on the YZ's and WR's from the beginning I dont know.

yeah mate i definatly will be holding it flat for a while lol i only ride one way and thats pinned everywhere :lol:
looks like i will just wait the 16 weeks :bonk:

  • SEDUCE

Posted March 06, 2012 - 01:07 AM

#18

Hey mate do u knw what the difference is in the 06 model one as it has a 5x part number
I am guessing this is not the right one by the look up parts http://www.ebay.com....984.m1423.l2649

  • SEDUCE

Posted March 15, 2012 - 01:33 AM

#19

No, The WR cover doesn't have the oil jet, so if you have your heart set on the oil-jet side cover (from the YFZ), you'll have to wait. Give me to the end of the day here to check and see if Yamaha USA has the cover in country.

HEY MATE, just a quick question does the new cover from the YFZ have the hole in the top of it for the oil line that comes off the head?????
I was looking at my mates 07 model WR450 and it doesnt have the line on it????

  • SEDUCE

Posted March 19, 2012 - 10:07 PM

#20

Hey guys anyone able to help me out, I have received the new cover off the YFZ450 and it has a outlet pipe under the waterpump
Listed below in pic it is item number 30 but it actually has a outlet on the cover.
What is this for i know its obviously for coolant but what connects to it as my old one off the 03 wr 450 doesnt have it.




 
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