2009 YAMAHA WR 450F check engine

4-4
ENGINE (Except for Canada)
EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM
This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions
of the engine.
Symptom Setting Checking
At full throttle
Hard breathing
Shearing noise
Whitish spark plug
↓
Lean mixtureIncrease main jet calibration no. (Gradual-
ly)Discoloration of spark plug→If tan color, it
is in good condition.
If cannot be corrected:
Clogged float valve seat
Clogged fuel hose
Clogged fuel cock
Check that the accelerator pump operates
smoothly.
At full throttle
Speed pick-up stops
Slow speed pick-up
Slow response
Sooty spark plug
↓
Rich mixtureDecrease main jet calibration no. (Gradual-
ly)Discoloration of spark plug→If tan color, it
is in good condition.
If cannot be corrected:
Clogged air filter
Fuel overflow from carburetor
Lean mixture Lower jet needle clip position. (1 groove
down)
The clip position is the jet needle groove on
which the clip is installed.
The positions are numbered from the top.
Check that the accelerator pump operates
smoothly. (except for rich mixture symp-
tom). Rich mixture Raise jet needle clip position. (1 groove up)
1/4–3/4 throttle
Hard breathing
Lack of speedLower jet needle clip position. (1 groove
down)
1/4–1/2 throttle
Slow speed pick-up
Poor accelerationRaise jet needle clip position. (1 groove up)
Closed to 1/4 throttle
Hard breathing
Speed downUse jet needle with a smaller diameter. Slow-speed-circuit passage
Clogged→Clean.
Overflow from carburetor
Closed to 1/4 throttle
Poor accelerationUse jet needle with a larger diameter.
Raise jet needle clip position. (1 groove up)
Poor response in the low to in-
termediate speedsRaise jet needle clip position.
If this has no effect, lower the jet needle clip
position.
Poor response when throttle is
opened quicklyCheck overall settings.
Use main jet with a lower calibration no.
Raise jet needle clip position. (1 groove up)
If these have no effect, use a main jet with
a higher calibration no. and lower the jet
needle clip position.Check air filter for fouling.
Check that the accelerator pump operates
smoothly.
Jet needleClip
Groove 7 Groove 6
Groove 5
Groove 4
Groove 3
Groove 2
Groove 1
Leaner
(Standard)
Richer

5-3
RADIATOR
HANDLING NOTE
Do not remove the radiator cap
when the engine and radiator are
hot. Scalding hot fluid and steam
may be blown out under pressure,
which could cause serious injury.
When the engine has cooled, open
the radiator cap by the following
procedure:
Place a thick rag, like a towel, over
the radiator cap, slowly rotate the
cap counterclockwise to the de-
tent. This procedure allows any re-
sidual pressure to escape. When
the hissing sound has stopped,
press down on the cap while turn-
ing counterclockwise and remove
it.
CHECKING THE RADIATOR
1. Inspect:
• Radiator core "1"
Obstruction→Blow out with com-
pressed air through rear of the ra-
diator.
Bent fin→Repair/replace.
INSTALLING THE RADIATOR
1. Install:
• Pipe 1 "1"
• Radiator hose 1 "2"
• Pipe 2 "3"
• Radiator hose 3 "4"
• Radiator hose 4 "5"2. Install:
• Radiator hose 2 "1"
• Left radiator "2"
3. Install:
• Catch tank hose "1"
• Right radiator "2"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
4. Install:
• Radiator guard "1"
First fit the inner hook portion "a" and
then the outer one "b" onto the radia-
tor.
5. Install:
• Catch tank "1"
• Bolt (catch tank) "2"
• Bolt (catch tank) "3"
• Catch tank hose "4"
• Catch tank breather hose "5"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.
Pipe 1:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Radiator hose 1:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Pipe 2:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Radiator hose 3:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Radiator hose 4:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Radiator hose 2:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Left radiator:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Right radiator:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (catch tank):
7 Nm (0.7 m•kg, 5.1
ft•lb)
Bolt (catch tank):
16 Nm (1.6 m•kg, 11
ft•lb)

5-8
CARBURETOR
HANDLING NOTE
Do not loosen the screw (throttle
position sensor) "1" except when
changing the throttle position sen-
sor due to failure because it will
cause a drop in engine perfor-
mance.
REMOVING THE PILOT SCREW
(For EUROPE)
1. Remove:
• Pilot screw "1"
To optimize the fuel flow at a small
throttle opening, each machine's pilot
screw has been individually set at the
factory. Before removing the pilot
screw, turn it in fully and count the
number of turns. Record this number
as the factory-set number of turns
out.
CHECKING THE CARBURETOR
1. Inspect:
• Carburetor body
Contamination→Clean.
• Use a petroleum based solvent for
cleaning. Blow out all passages and
jets with compressed air.
• Never use a wire.
2. Inspect:
•Main jet "1"
• Pilot jet "2"
• Needle jet "3"
• Starter jet "4"
•Pilot air jet "5"
• Leak jet "6"
Damage→Replace.
Contamination→Clean.
• Use a petroleum based solvent for
cleaning. Blow out all passages and
jets with compressed air.
• Never use a wire.
CHECKING THE NEEDLE VALVE
1. Inspect:
• Needle valve "1"
• Valve seat "2"
Grooved wear "a" →Replace.
Dust "b" →Clean.
• Filter "c"
Clogged→Clean.
CHECKING THE THROTTLE
VALVE
1. Check:
• Free movement
Stick→Repair or replace.
Insert the throttle valve "1" into the
carburetor body, and check for free
movement.
CHECKING THE JET NEEDLE
1. Inspect:
• Jet needle "1"
Bends/wear→Replace.
• Clip groove
Free play exists/wear→Replace.
MEASURING AND ADJUSTING
THE FLOAT HEIGHT
1. Measure:
• Float height "a"
Out of specification→Adjust.
Measurement and adjustment
steps:
a. Hold the carburetor in an upside
down position.
• Slowly tilt the carburetor in the op-
posite direction, then take the mea-
surement when the needle valve
aligns with the float arm.
• If the carburetor is level, the weight
of the float will push in the needle
valve, resulting in an incorrect mea-
surement.
b. Measure the distance between
the mating surface of the float
chamber and top of the float using
a vernier calipers.
The float arm should be resting on the
needle valve, but not compressing
the needle valve.
c. If the float height is not within
specification, inspect the valve
seat and needle valve.
d. If either is worn, replace them
both.
Float height:
8.0 mm (0.31 in)

5-19
CAMSHAFTS
INSTALLING THE CAMSHAFT
1. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"
Installation steps:
a. Turn the crankshaft counterclock-
wise with a wrench.
• Apply the molybdenum disulfide oil
on the camshafts.
• Apply the engine oil on the decom-
pression system.
b. Align the T.D.C. mark "a" on the
rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
c. Fit the timing chain "3" onto both
camshaft sprockets and install the
camshafts on the cylinder head.
The camshafts should be installed
onto the cylinder head so that the
punch mark "c" on the exhaust cam-
shaft and the punch mark "d" on the
intake camshaft must align with the
cylinder head surface, as shown in
the illustration.
Do not turn the crankshaft during
the camshaft installation. Damage
or improper valve timing will re-
sult.
d. Install the clips, camshaft caps "4"
and bolts (camshaft cap) "5".
• Before installing the clips, cover the
cylinder head with a clean rag to
prevent the clips from into the cylin-
der head cavity.
• Apply the molybdenum disulfide oil
on the thread of the bolts (camshaft
cap).
• Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.
The bolts (camshaft cap) must be
tightened evenly, or damage to the
cylinder head, camshaft caps, and
camshaft will result.
2. Install:
• Timing chain tensioner
Installation steps:
a. While pressing the tensioner rod
lightly with fingers, use a thin
screwdriver and wind the tension-
er rod up fully clockwise.
b. With the rod fully wound and the
chain tensioner UP mark "a" fac-
ing upward, install the gasket "1",
the timing chain tensioner "2", and
the gasket "3", and tighten the bolt
"4" to the specified torque.c. Release the screwdriver, check
the tensioner rod to come out and
tighten the gasket "5" and the cap
bolt "6" to the specified torque.
3. Turn:
• Crankshaft
Counterclockwise several turns.
4. Check:
• Rotor T.D.C. mark
Align with the crankcase align
mark.
• Camshaft match marks
Align with the cylinder head sur-
face.
Out of alignment→Adjust.
Bolt (camshaft cap):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (timing chain ten-
sioner):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Tensioner cap bolt:
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)

5-33
CLUTCH
2. Install:
• Lock washer "1"
• Nut (clutch boss) "2"
Make sure to tighten to specifica-
tion; otherwise, it may damage the
other part that is fastened togeth-
er.
• Install the lock washer with its con-
caves fitted over the convexes of
the clutch boss.
• Use the clutch holding tool "3" to
hold the clutch boss.
A. For USA and CDN
B. Except for USA and CDN
3. Bend the lock washer "1" tab.
4. Install:
• Friction plate "1"
• Clutch plate 1 [t=2.0 mm (0.079
in)] "2"• Clutch plate 2 [t=1.6 mm (0.063
in)] "3"
• Install the clutch plates and friction
plates alternately on the clutch
boss, starting with a friction plate
and ending with a friction plate.
• Apply the engine oil on the friction
plates and clutch plates.
• Check the clutch plate for thickness
and install 4 thicker ones "a" on the
engine side and 3 thinner ones "b"
on the outside.
5. Install:
•Bearing "1"
• Washer "2"
• Circlip "3"
To push rod 1 "4".
Apply the engine oil on the bearing
and washer.
6. Install:
• Push rod 2 "1"
• Ball "2"
• Push rod 1 "3"
Apply the engine oil on the push rod
1, 2 and ball.
7. Install:
• Pressure plate "1"
8. Install:
• Clutch spring
• Bolt (clutch spring)
Tighten the bolts in stage, using a
crisscross pattern.
9. Install:
• Gasket (clutch cover) "1"
• Dowel pin "2"
10. Install:
• Clutch cover "1"
• Bolt (clutch cover)
Tighten the bolts in stage, using a
crisscross pattern.
Nut (clutch boss):
75 Nm (7.5 m•kg, 54
ft•lb)
Clutch holding tool:
YM-91042/90890-04086
Bolt (clutch spring):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (clutch cover):
10 Nm (1.0 m•kg, 7.2
ft•lb)