WR450 Starter Update '03 to '04 Part Numbers

I forgot to say keep the old side cover if you puncture the new one I think you can get the bushing out and press it into the old case. Everything else looks identical. :)

Great job Indy! This change is a very worthwhile improvement to our less than well engineered starter system. Now, if a technically savvy someone could only come up with the specifications for the bushing in the new 2004 Left Side Case PN 5TJ-15411-10-00, then we could have a bushing made and save most of the $92.49 cost of the part.

If you have the ability to make the bushing go ahead. I would make it .001" larger diameter than the shaft for a snug fit. Make it out of steel since the shaft is no supposed to rotate. I am just going to keep the old case in the event I puncture or crack this case. :)

This IS a PERFECT EXAMPLE of why this is the ABSOLUTE BEST WEBSITE in INTERNET HISTORY!!!! :D :D :D:):D The superb teamwork and camraderie here IS really overwhelming!

I am glad to be a part of it!!

Yea, its a shame Yamaha was of no help.

As far as making bushings are concerned, I would get the clearance off the new parts and try to duplicate on the old parts. Don't just guess.

Hey guys, If someone could get the EXACT measurements of that bushing, I have a friend that owns a machine shop and I'am sure he could duplicate it. Have we determined for sure that the hole where the bushing goes is the same size in both case's? If so it would just be a matter of heating up our old case while freezing the bushing and it should press in pretty easily. Once my guy had the demensions he could whip out a whole bunch of them. I don't want to buy a new case just to measure the bushing, so hopfully one of you guys that have already bought one could take it to a machine shop to have it miked.

Dimensions for the bushing are on this post in earlier replys.

Well if the bushing demensions on on this post I can't find it. I would be surprised if it was there because, Indy, you were the first one to get the new parts just last week.

OK here is the bushing dimensions:

bushing ID is 0.394"-0.395" diameter bore (for 10 mm shaft)

bushing OD is 0.471"-0.472" diameter (for 12mm hole)

Bushing length is 3/8" or 0.370"-0.375"

Material is steel. Yamaha chose to slit the bushing the length of the shaft to allow easier press fitting into the case without cracking the case during the installation. You can avoid this by sticking to the tight tolerances listed above. :)

I just finished the up-grade to the 04 starter parts & found the job fairly easy to perform :D. While apart I inspected the old parts for any sign of damage and found none at all :D :D. I have had the TSB performed but have not had a failed Key to date so I am hopeing that this is in fact the fix for any problem I might have encoutered relateing to the E-sart. Now I am truely ready to take my first ride this Sunday after a very long and very cold winter with atleast piece of mind that I won't be pushing my steed out of the woods for a faild key :D. Thanks to all that have made this up-grade possible :D.

Smoke :)

So, what's the best price total from dealers so far for all the parts necessary to do the 04 conversion?

$300.00 is a good price with the side case. Make a bushing and $230. is a good price. :)

Guys, I just sold my WR450 a week ago, AND , I got a call yesterday that my updated parts are in. I will sell them for what I paid for them plus shipping. I got the parts for cost, and I paid 189.00 dollars. That is for the case and all, no bushing needed. If anybody wants these parts, PM or E mail me. I do accept Paypal also, so no worries about getting screwed. :)

Dave

P.S. Sorry, but I went back to a 2 stroke, but I will still check in to this forum. Great guys and converstion!!

Guys, I just sold my WR450 a week ago, AND , I got a call yesterday that my updated parts are in. I will sell them for what I paid for them plus shipping. I got the parts for cost, and I paid 189.00 dollars. That is for the case and all, no bushing needed. If anybody wants these parts, PM or E mail me. I do accept Paypal also, so no worries about getting screwed. :)

Dave

P.S. Sorry, but I went back to a 2 stroke, but I will still check in to this forum. Great guys and converstion!!

I'll TAKE THEM VB!!! Check your PM's!!

Guys, I just sold my WR450 a week ago, AND , I got a call yesterday that my updated parts are in. I will sell them for what I paid for them plus shipping. I got the parts for cost, and I paid 189.00 dollars. That is for the case and all, no bushing needed. If anybody wants these parts, PM or E mail me. I do accept Paypal also, so no worries about getting screwed. :)

Dave

Thank you Dave! And this is why I love TT!! :D

No problem, Dave... I wish everybody at least had a dealer that helped out like mine did.

Dave

I have an Idea for you Yamaha riders who have got the shaft from them. Everyone who has had this problem go to the big supercrosses and races in your area and bring huge signs "Yamahas are screwing there buyers ask me!" or "recall on 03wr450's" If its in view the camaras will get it and maybee that will help, If you had people all accross the USA doing that Just an idea

Hey guys here's the Genuine Yamaha part number for the bushing in the side cover. ( update 03 cover to 04 specs )

90380-10002

Hope this saves you all a few dollars.

I just fitted a new starter clutch, clutch gear ( attached to the flywheel ) and idle gear at Yamahas expence ( and the starter clutch and clutch gear were badly worn where they mate, after 3000klm ) and i paid for the torque limiter, torque limiter cover, washers and bushing at around $250 AUD RRP

Cheers

What did you get for your 450?

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