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aussie_thumper

03WR450 mods

20 posts in this topic

.I just got a preloved wr450 2003. The thing is stock standard hasn't had a thing done except normal servicing. Only 700 km on the clock.

I was checking out "thumperfaqs" website, there is some great info there as well as this site but the site is focused on 250 engines not 450's. Can all the mods for the 250 be done on a 450 as well ?

Any other advice and recommendations to make my bike perform better and be more reliable would be highly appreciated also.

By the way this site is awesome, never found as much valuable info in one place.

Cheers

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I've got the 03 wr450 as well. Not really sure what the differences are between tha Aussie version and the US version. Here's what you can do and what I did:

1. Cut the grey wire

2. Change to a YZ throttle stop (or shorten the WR stop).

3. Remove the intake snorkel

4. Remove the exhaust restrictor and add the silent insert if you like. (I went with a YZ exhaust)

5. Re-jet with JD Jetting kit (or YZ Needle) after all mods.

6. Swamp proof. re-route crankcase breather hose and two top carb vent lines into air box.

7. New rear spring (I weigh 250 lbs and used a 6.4 racetech).

8. Radiator guards. I use Flatland Racing and have no complaints.

There are a bunch more things you can do too. All of these mods are detailed somewhere on this forum, just search.

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I've got the 03 wr450 as well. Not really sure what the differences are between tha Aussie version and the US version. Here's what you can do and what I did:

1. Cut the grey wire

2. Change to a YZ throttle stop (or shorten the WR stop).

3. Remove the intake snorkel

4. Remove the exhaust restrictor and add the silent insert if you like. (I went with a YZ exhaust)

5. Re-jet with JD Jetting kit (or YZ Needle) after all mods.

6. Swamp proof. re-route crankcase breather hose and two top carb vent lines into air box.

7. New rear spring (I weigh 250 lbs and used a 6.4 racetech).

8. Radiator guards. I use Flatland Racing and have no complaints.

There are a bunch more things you can do too. All of these mods are detailed somewhere on this forum, just search.

You shouldn't need to do 1,2,3,(4 maybe)5 on the oz version. :)

Look into the starter upgrade changing 03 to 04.

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Have heard about the starter upgrade before. There does'nt seem to be any sign of problems so far, something to look foward too I guess :)

Can anyone tell me the main differences between the u.s & oz version.

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Im in the same spot as you-just got myself an 03 and am having trouble working out hat is what from the US bikes to ours??? Cant really see any snorkel to take out etc

Ive bought the parts for the 04 starter upgrade, cost around $300 but Ive heard will be worth it to avoid it shidding itself. Also just ordered a JD jetting kit as my bike backfires and carries on...

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Have heard about the starter upgrade before. There does'nt seem to be any sign of problems so far, something to look foward too I guess :)

Can anyone tell me the main differences between the u.s & oz version.

I had to soften up my suspension just by adjusting the clickers, I think ours are set "hard" to comply with ADR.

The US version comes anti pollution crap your 03 does not.

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Im in the same spot as you-just got myself an 03 and am having trouble working out hat is what from the US bikes to ours??? Cant really see any snorkel to take out etc

Ive bought the parts for the 04 starter upgrade, cost around $300 but Ive heard will be worth it to avoid it shidding itself. Also just ordered a JD jetting kit as my bike backfires and carries on...

The Oz version does not have a snorkel, except 05 I think.

There is no grey wire to limit the revs.

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Mate where did you get your 04 upgrade from if you don't mind me asking, I'm sick of kicking....Thanks

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Any yammi shop will be able to supply the bits you need (or any other shop at a premuim), the parts listed below are what I have bought but havent put in yet, I got the list from a few guys on Dirtbikeworld.net

Damper Ass 5TJ-15560-00 $256

2XSHIMS 90201105A8 $6

COVER 5TJ-15498-00 $44

BUSH 90308-10002 $3.90

Apparently this is an easy mod to do yourself-I just havent had the time, plus Im still trying to work out how to take my friggen bash plate off :) Ive taken all the bolts out and its still freakin stuck on!! I know it will be something easy and make me feel stupid but....

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The US emission standards are tougher than the OZ ones so our WR's are less restricted.

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Are you sure that the parts you list are all the bit you need?

I recently went to a Yamaha mechanic and asked to look at their factory warranty report regarding this 03 to 04 starter upgrade. They said they had done heeps of upgrades under warranty and the whole flywheel case and other parts also need replacing to fit the new starter idle gear. They quoted me $1500 for Just the parts.

I'm really interested to see if your upgrade works. Please let us know because I've given up on the starter on my WR.

As far as I can tell , there are 3 design problems with the starter and this upgrade will only fix one of the problems.

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Heres the link mate- http://www.dirtbikeworld.net/dirtbike/showthread.php?t=10923&page=2&pp=15&highlight=starter

Its soo bloody typical, you get so many conflicting stories from so manyt different people you dont know who to believe-some bike shops I called said they had never had to fix such a failure in the wr's other said they had quite a few. But the shop I ended up getting the parts from said the fix would be sufficient, but then again he said it was mainly in the early model 03 :)

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Just thought I would let you know that my 03 has got 4500kms, no mods to the starter and she still go's just as hard as the day I got her :)

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Thats good mate!! But I bought my upgrade for the peace of mind-I would rather spend the $300 now and be happy than spend the $1800 if it went......

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Many of us have done the starter upgrade with no problems afterwards. There is a work around so you do not have to replace the expensive side case. There's a website was all the instructions, etc.

Mucho thanks to the TT guys who put it together! :)

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The thing Im wondering though is if you read the link I posted the parts required arnt the same as the TT ones, so am I still at risk?? arrrgghhhhhh :)

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Look into the starter upgrade changing 03 to 04.

So on a US model, is there a way to tell that that upgrade was done without taking the side cover out ?

thanks,

bruno.

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I did the upgrade a year ago on mine.You do not need the main side cover just the little one that goes over the new gear.If it hassn't taken a crap yet just take the two bolts out of the small round cover then remove.Remove the gear and any washers.Tap bush into shaft hole at back of case ( thats why you don't need the new side cover ) .There are two washers one on each side of the new gear shaft .I cant remember but i think i may have had to get them to.Put the new gear in and bolt the new cover on.10 minutes max.My starter recently took a dump and it appeared to be like a flat battery.It ended up being the little metal bearing at the brush end.Yamaha doesn't sell this but i went to a bearing shop and bought one for $2.90 and had a friend machine it down,also replaced the brushes $28.It works now and it was a lot cheaper than $450 for a new starter.I live near geelong if you need info or are close by pm me.

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