2009 YAMAHA WR 450F checking oil

3-23
CHASSIS
6. Install:
• Chain joint "1"
• O-ring "2"
• Drive chain "3"
• Link plate "4"
When installing the drive chain, apply
the lithium soap base grease on the
chain joint and O-rings.
7. Install:
• Link plate
• Press the link plate onto the chain
joint using a drive chain riveter "5".
• Rivet the end of the chain joint us-
ing a drive chain riveter.
• After riveting the chain joint, make
sure its movement is smooth.
8. Lubricate:
• Drive chain
ADJUSTING THE DRIVE CHAIN
SLACK
1. Elevate the rear wheel by placing
the suitable stand under the en-
gine.
2. Check:
• Drive chain slack "a"
Above the seal guard installation
bolt.Out of specification→Adjust.
Before checking and/or adjusting, ro-
tate the rear wheel through several
revolutions and check the slack sev-
eral times to find the tightest point.
Check and/or adjust the drive chain
slack with the rear wheel in this "tight
chain" position.
3. Adjust:
• Drive chain slack
Drive chain slack adjustment
steps:
a. Loosen the axle nut "1" and lock-
nuts "2".
b. Adjust the drive chain slack by
turning the adjusters "3".
c. Turn each adjuster exactly the
same amount to maintain correct
axle alignment. (There are marks
"a" on each side of the drive chain
puller alignment.) NOTICE: Im-
proper drive chain slack will
overload the engine as well as
other vital parts of the motorcy-
cle and can lead to chain slip-
page or breakage. To prevent
this from occurring, keep the
drive chain slack within the
specified limits.
Turn the adjuster so that the drive
chain is in line with the sprocket, as
viewed from the rear.
d. Tighten the axle nut while pushing
down the drive chain.
e. Tighten the locknuts.
CHECKING THE FRONT FORK
1. Inspect:
• Front fork smooth action
Operate the front brake and
stroke the front fork.
Unsmooth action/oil leakage→
Repair or replace.
CLEANING THE FRONT FORK OIL
SEAL AND DUST SEAL
1. Remove:
•Protector
• Dust seal "1"
Use a thin screw driver, and be care-
ful not to damage the inner fork tube
and dust seal.
2. Clean:
• Dust seal "a"
• Oil seal "b"
• Clean the dust seal and oil seal af-
ter every run.
• Apply the lithium soap base grease
on the inner tube.
Drive chain lubricant:
SAE 10W-30 motor oil
or suitable chain lubri-
cants
Drive chain slack:
48–58 mm (1.9–2.3 in)
To tighten→Turn the adjuster "3"
counterclockwise.
To loosen→Turn the adjuster "3"
clockwise and push wheel for-
ward.
Axle nut:
125 Nm (12.5 m•kg, 90
ft•lb)
Locknut:
19 Nm (1.9 m•kg, 13
ft•lb)

3-24
CHASSIS
RELIEVING THE FRONT FORK
INTERNAL PRESSURE
If the front fork initial movement feels
stiff during a run, relieve the front fork
internal pressure.
1. Elevate the front wheel by placing
a suitable stand under the engine.
2. Remove the air bleed screw "1"
and release the internal pressure
from the front fork.
3. Install:
• Air bleed screw
ADJUSTING THE FRONT FORK
REBOUND DAMPING FORCE
1. Adjust:
• Rebound damping force
By turning the adjuster "1".
• STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
ADJUSTING THE FRONT FORK
COMPRESSION DAMPING FORCE
1. Remove:
• Rubber cap
2. Adjust:
• Compression damping force
By turning the adjuster "1".
• STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
3. Install:
• Rubber cap
CHECKING THE REAR SHOCK
ABSORBER
1. Inspect:
• Swingarm smooth action
Abnormal noise/unsmooth action
→Grease the pivoting points or
repair the pivoting points.
Damage/oil leakage→Replace.
ADJUSTING THE REAR SHOCK
ABSORBER SPRING PRELOAD
1. Elevate the rear wheel by placing
the suitable stand under the en-
gine.
2. Remove:
• Rear frame
3. Measure:
• Spring fitting length
The I.D. mark "a" is marked at the end
of the spring.
Air bleed screw:
1 Nm (0.1 m•kg, 0.7
ft•lb)
Stiffer "a" →Increase the re-
bound damping force. (Turn
the adjuster "1" in.)
Softer "b" →Decrease the re-
bound damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)
Standard position:
8 clicks out
Stiffer "a" →Increase the com-
pression damping force. (Turn
the adjuster "1" in.)
Softer "b" →Decrease the com-
pression damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)
Standard position:
9 clicks out
Standard fitting length:
I.D. MARK/
Q'TYLength
Pink/1 252.5 mm
(9.94 in)
* 251.5 mm
(9.90 in)
* For EUROPE

3-29
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:
• Spark plug
2. Inspect:
• Electrode "1"
Wear/damage→Replace.
• Insulator color "2"
Normal condition is a medium to
light tan color.
Distinctly different color→Check
the engine condition.
When the engine runs for many hours
at low speeds, the spark plug insula-
tor will become sooty, even if the en-
gine and carburetor are in good
operating condition.
3. Measure:
• Plug gap "a"
Use a wire gauge or thickness
gauge.
Out of specification→Regap.
4. Clean the plug with a spark plug
cleaner if necessary.
5. Tighten:
• Spark plug
• Before installing a spark plug, clean
the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug
before torquing to specification "b".
CHECKING THE IGNITION TIMING
1. Remove:
• Timing mark accessing screw "1"
2. Attach:
• Timing light
• Digital tachometer
To the ignition coil lead (orange
lead"1").
3. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section.
4. Check:
• Ignition timing
Visually check the stationary
pointer "a" is within the firing
range "b" on the rotor.
Incorrect firing range→Check ro-
tor and pickup assembly.
5. Install:
• Timing mark accessing screw
CHECKING AND CHARGING THE
BATTERY
Batteries generate explosive hy-
drogen gas and contain electrolyte
which is made of poisonous and
highly caustic sulfuric acid. There-
fore, always follow these preven-
tive measures:
• Wear protective eye gear when
handling or working near batter-
ies.• Charge batteries in a well-venti-
lated area.
• Keep batteries away from fire,
sparks or open flames (e.g.,
welding equipment, lighted ciga-
rettes).
• DO NOT SMOKE when charging
or handling batteries.
• KEEP BATTERIES AND ELEC-
TROLYTE OUT OF REACH OF
CHILDREN.
• Avoid bodily contact with elec-
trolyte as it can cause severe
burns or permanent eye injury.
FIRST AID IN CASE OF BODILY
CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15
minutes and get immediate med-
ical attention.
INTERNAL
• Drink large quantities of water or
milk followed with milk of magne-
sia, beaten egg or vegetable oil.
Get immediate medical attention.
Charging time, charging amperage
and charging voltage for an MF
battery are different from those of
conventional batteries. The MF
battery should be charged as ex-
plained in the charging method il-
lustrations. If the battery is
overcharged, the electrolyte level
will drop considerably. Therefore,
take special care when charging
the battery.
Since MF batteries are sealed, it is
not possible to check the charge state
of the battery by measuring the spe-
cific gravity of the electrolyte. There-
fore, the charge of the battery has to
be checked by measuring the voltage
at the battery terminals.
1. Remove:
• Seat
2. Disconnect:
• Battery leads
(from the battery terminals)
First, disconnect the negative bat-
tery lead "1", and then the positive
battery lead "2".
Spark plug gap:
0.7–0.8 mm (0.028–
0.031 in)
Spark plug:
13 Nm (1.3 m•kg, 9.4
ft•lb)
Timing light:
YM-33277-A/90890-
03141

3-33
ELECTRICAL
6. Install:
•Battery
• Battery band
7. Connect:
• Battery leads
(to the battery terminals)
First, connect the positive lead "1",
then the negative lead "2".
8. Check:
• Battery terminals
Dirt→Clean with a wire brush.
Loose connection→Connect
properly.
9. Lubricate:
• Battery terminal
10. Install:
• Seat
CHECKING THE FUSE
To avoid a short circuit, always set
the main switch to "OFF" when
checking or replacing a fuse.
1. Remove:
• Seat
• Fuse cover
2. Check:
• Continuity
Checking steps:
a. Remove the fuse "1".
b. Connect the pocket tester to the
fuse and check the continuity.
Set the pocket tester selector to " Ω×
1".
2. Reserve fuse
c. If the pocket tester indicates "∞",
replace the fuse.
3. Replace:
• Blown fuse
Replacement steps:
a. Set the main switch to "OFF".
b. Install a new fuse of the correct
amperage.
c. Set on the switches to verify if the
electrical circuit is operational.
d. If the fuse immediately blows
again, check the electrical circuit.
Never use a fuse with an amperage
rating other than that specified. Im-
provising or using a fuse with the
wrong amperage rating may cause
extensive damage to the electrical
system, cause the starting and ig-
nition systems to malfunction and
could possibly cause a fire.
4. Install:
• Fuse cover
•Seat
REPLACING THE HEADLIGHT
BULBS
1. Remove:
• Headlight
Refer to "REMOVING THE SEAT,
FUEL TANK AND SIDE COV-
ERS" section.2. Remove:
• Headlight bulb holder cover "1"
3. Remove:
• Headlight bulb holder "1"
Remove the headlight bulb holder by
pushing it in and turning it counter-
clockwise.
4. Remove:
• Headlight bulb
Since the headlight bulb gets ex-
tremely hot, keep flammable prod-
ucts and your hands away from the
bulb unit it has cooled down.
5. Install:
• Headlight bulb
Avoid touching the glass part of
the headlight bulb to keep it free
form oil, otherwise the transparen-
cy of the glass, the life of the bulb
and the luminous flux will be ad-
versely affected. If the headlight
bulb gets soiled, thoroughly clean
it with a cloth moistened with alco-
hol or lacquer thinner.
6. Install:
• Headlight bulb holder
7. Install:
• Headlight bulb holder cover
8. Install:
• Headlight
Refer to "REMOVING THE SEAT,
FUEL TANK AND SIDE COV-
ERS" section. Recommended lubricant:
Lithium soap base
grease
Pocket tester:
YU-3112-C/90890-
03112
Items Amperage
ratingQ'ty
Main fuse 10 A 1
Headlight:
7 Nm (0.7 m•kg, 5.1
ft•lb)

5-26
VALVES AND VALVE SPRINGS
CHECKING THE VALVE SPRINGS
1. Measure:
• Valve spring free length "a"
Out of specification→Replace.
2. Measure:
• Compressed spring force "a"
Out of specification→Replace.
b. Installed length
3. Measure:
• Spring tilt "a"
Out of specification→Replace.CHECKING THE VALVE LIFTERS
1. Inspect:
• Valve lifter
Scratches/damage→Replace
both lifters and cylinder head.
INSTALLING THE VALVES
1. Apply:
• Molybdenum disulfide oil
Onto the valve stem and valve
stem seal.
2. Install:
• Valves "1"
• Valve spring seats "2"
• Valve stem seals "3"
• Valve springs "4"
• Valve spring retainers "5"
• Make sure that each valve is in-
stalled in its original place, also re-
ferring to the painted color as
follows.
Intake (middle) "a": blue
Intake (right/left) "b": gray
Exhaust "c": brown
• Install the valve springs with the
larger pitch "d" facing upward.
e. Smaller pitch3. Install:
• Valve cotters
While compressing the valve spring
with a valve spring compressor "1" in-
stall the valve cotters.
4. To secure the valve cotters onto
the valve stem, lightly tap the
valve tip with a piece of wood.
Hitting the valve tip with excessive
force could damage the valve.
5. Install:
• Adjusting pad "1"
• Valve lifter "2"
• Apply the molybdenum disulfide oil
on the valve stem end.
• Apply the engine oil on the valve lift-
ers.
• Valve lifter must turn smoothly
when rotated with a finger.
• Be careful to reinstall valve lifters
and pads in their original place.
Free length (valve
spring):
Intake:
39.46 mm (1.55 in)
: 38.46 mm
(1.51 in)
Exhaust:
37.61 mm (1.48 in)
: 36.61 mm
(1.44 in)
Compressed spring
force:
Intake:
130.2–149.8 N at 27.87
mm (13.28–15.28 kg at
27.87 mm, 29.27–
33.68 lb at 1.10 in)
Exhaust:
123.1–141.7 N at 28.38
mm (12.55–14.45 kg at
28.38 mm, 27.67–
31.85 lb at 1.12 in)
Spring tilt limit:
Intake:
2.5°/1.7 mm (0.067 in)
Exhaust:
2.5°/1.6 mm (0.063 in)
Valve spring compres-
sor:
YM-4019/90890-04019

5-29
CYLINDER AND PISTON
You cannot measure the end gap on
the expander spacer of the oil control
ring. If the oil control ring rails show
excessive gap, replace all three rings.
CHECKING THE PISTON PIN
1. Inspect:
• Piston pin
Blue discoloration/grooves→Re-
place, then inspect the lubrication
system.
2. Measure:
• Piston pin-to-piston clearance
Measurement steps:
a. Measure the outside diameter
(piston pin) "a".
If out of specification, replace the
piston pin.
b. Measure the inside diameter (pis-
ton) "b".
c. Calculate the piston pin-to-piston
clearance with the following for-mula.
d. If out of specification, replace the
piston.
INSTALLING THE PISTON RING
AND PISTON
1. Install:
•Piston ring
Onto the piston.
• Be sure to install the piston rings so
that the manufacturer's marks or
numbers are located on the upper
side of the rings.
• Lubricate the piston and piston
rings liberally with engine oil.
2. Position:
•Top ring
• 2nd ring
• Oil ring
Offset the piston ring end gaps as
shown.
a. Top ring end
b. 2nd ring end
c. Oil ring end (upper)
d. Oil ring
e. Oil ring end (lower)
3. Install:
•Piston "1"
• Piston pin "2"
• Piston pin clip "3"
• Apply engine oil onto the piston pin and piston.
• Be sure that the arrow mark "a" on
the piston points to the exhaust side
of the engine.
• Before installing the piston pin clip,
cover the crankcase with a clean
rag to prevent the piston pin clip
from falling into the crankcase.
• Install the piston pin clips with their
ends facing downward.
INSTALLING THE CYLINDER
1. Install:
• Dowel pins
• Cylinder gasket "1"
• Cylinder "2"
Install the cylinder with one hand
while compressing the piston rings
with the other hand.
• Pass the timing chain "3"
through the timing chain cavity.
• Be careful not to damage the tim-
ing chain guide "4" during instal-
lation.
2. Install:
• Bolt (cylinder) End gap:
Standard
Top
ring0.20–0.30
mm (0.008–
0.012 in)0.55 mm
(0.022 in)
2nd
ring0.35–0.50
mm (0.014–
0.020 in)0.85 mm
(0.033 in)
Oil
ring0.20–0.50
mm (0.01–
0.02 in)—
Outside diameter (piston
pin):
17.991–18.000 mm
(0.7083–0.7087 in)
Inside diameter (piston):
18.004–18.015 mm
(0.7088–0.7093 in)
Piston pin-to-piston clearance =
Inside diameter (piston) "b" -
Outside diameter (piston pin)
"a"
Piston pin-to-piston
clearance:
0.004–0.024 mm
(0.00016–0.00094 in)
:0.07 mm (0.003
in)
Bolt (cylinder):
10 Nm (1.0 m•kg, 7.2
ft•lb)
New

5-32
CLUTCH
REMOVING THE CLUTCH BOSS
1. Remove:
•Nut "1"
• Lock washer "2"
• Clutch boss "3"
Straighten the lock washer tab and
use the clutch holding tool "4" to hold
the clutch boss.
A. For USA and CDN
B. Except for USA and CDN
CHECKING THE CLUTCH
HOUSING AND BOSS
1. Inspect:
• Clutch housing "1"
Cracks/wear/damage→Replace.
• Clutch boss "2"
Scoring/wear/damage→Replace.
CHECKING THE PRIMARY DRIVEN
GEAR
1. Check:
• Circumferential play
Free play exists→Replace.
• Gear teeth "a"
Wear/damage→Replace.CHECKING THE CLUTCH
SPRINGS
1. Measure:
• Clutch spring free length "a"
Out of specification→Replace
springs as a set.
CHECKING THE FRICTION
PLATES
1. Measure:
• Friction plate thickness
Out of specification→Replace
friction plate as a set.
Measure at all four points.
CHECKING THE CLUTCH PLATES
1. Measure:
• Clutch plate warpage
Out of specification→Replace
clutch plate as a set.
Use a surface plate "1" and thick-
ness gauge "2".CHECKING THE PUSH LEVER
SHAFT
1. Inspect:
• Push lever shaft "1"
Wear/damage→Replace.
CHECKING THE PUSH ROD
1. Inspect:
• Push rod 1 "1"
• Bearing "2"
• Washer "3"
• Push rod 2 "4"
•Ball "5"
Wear/damage/bend→Replace.
INSTALLING THE PUSH LEVER
SHAFT
1. Install:
• Push lever shaft "1"
• Apply the lithium soap base grease
on the oil seal lip.
• Apply the engine oil on the push le-
ver shaft.
INSTALLING THE CLUTCH
1. Install:
• Primary driven gear "1"
• Thrust washer "2"
• Clutch boss "3"
Apply the engine oil on the primary
driven gear inner circumference.
Clutch holding tool:
YM-91042/90890-04086
Clutch spring free
length:
50.0 mm (1.97 in)
: 49.0 mm (1.93
in)
Friction plate thickness:
2.92–3.08 mm (0.115–
0.121 in)
: 2.8 mm (0.110
in)
Warp limit:
0.1 mm (0.004 in)

5-36
OIL FILTER ELEMENT AND WATER PUMP
REMOVING THE IMPELLER
SHAFT
1. Remove:
• Impeller "1"
• Washer "2"
• Impeller shaft "3"
Hold the impeller shaft on its width
across the flats "a" with spanners,
etc. and remove the impeller.
REMOVING THE OIL SEAL
It is not necessary to disassemble the
water pump, unless there is an abnor-
mality such as excessive change in
coolant level, discoloration of coolant,
or milky transmission oil.
1. Remove:
• Bearing "1"
• Oil seal "2"CHECKING THE IMPELLER SHAFT
1. Inspect:
• Impeller shaft "1"
Bend/wear/damage→Replace.
Fur deposits→Clean.
CHECKING THE BEARING
1. Inspect:
•Bearing
Rotate inner race with a finger.
Rough spot/seizure→Replace.
CHECKING THE OIL SEAL
1. Inspect:
• Oil seal "1"
Wear/damage→Replace.
INSTALLING THE OIL SEAL
1. Install:
• Oil seal "1"
• Apply the lithium soap base grease
on the oil seal lip.
• Install the oil seal with its manufac-
ture's marks or numbers facing the
right crankcase cover "2".
2. Install:
•Bearing "1"
Install the bearing by pressing its out-
er race parallel.
INSTALLING THE IMPELLER
SHAFT
1. Install:
• Impeller shaft "1"
• Washer "2"
• Impeller "3"
• Take care so that the oil seal lip is
not damaged or the spring does not
slip off its position.
• When installing the impeller shaft,
apply the engine oil on the oil seal
lip, bearing and impeller shaft. And
install the shaft while turning it.
• Hold the impeller shaft on its width
across the flats "a" with spanners,
etc. and install the impeller.
INSTALLING THE RIGHT
CRANKCASE COVER
1. Install:
• Dowel pin "1"
• O-ring "2"
•Collar "3"
• Gasket "4"
Apply the lithium soap base grease
on the O-ring.
Impeller:
14 Nm (1.4 m•kg, 10
ft•lb)