2016 YAMAHA WR 450F Fuel stop

1
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS............................................................ 1-1
DESCRIPTION .................................................................................................. 1-4
IDENTIFICATION ............................................................................................. 1-5
VEHICLE IDENTIFICATION NUMBER ...................................................... 1-5
ENGINE SERIAL NUMBER ....................................................................... 1-5
VEHICLE EMISSION CONTROL INFORMATION LABEL......................... 1-5
INCLUDED PARTS .......................................................................................... 1-6
SPARK PLUG WRENCH ........................................................................... 1-6
NIPPLE WRENCH...................................................................................... 1-6
HANDLEBAR PROTECTOR .. .................................................................... 1-6
FUEL HOSE JOINT COVER ...................................................................... 1-6
COUPLER FOR CONNECTING OPTIONAL PART................................... 1-6
IMPORTANT INFORMATION .......................................................................... 1-7
PREPARATION FOR REMOVAL A ND DISASSEMBLY............................ 1-7
REPLACEMENT PARTS............................................................................ 1-7
GASKETS, OIL SEALS AND O-RINGS ..................................................... 1-8
LOCK WASHERS/PLATES AND COTTER PINS ...................................... 1-8
BEARINGS AND OIL SEALS ..................................................................... 1-8
CIRCLIPS ................................................................................................... 1-8
BASIC SERVICE INFORMATION .................................................................... 1-9
ELECTRICAL SYSTEM.......... .................................................................... 1-9
SPECIAL TOOLS ........................................................................................... 1-13
CONTROL FUNCTIONS ................................................................................ 1-18
INDICATOR LIGHTS AND WARNING LIGHTS ....................................... 1-18
ENGINE STOP SWITCH .......................................................................... 1-18
START SWITCH....................................................................................... 1-18
CLUTCH LEVER ................................................................................... ... 1-18
SHIFT PEDAL .......................................................................................... 1-19
KICKSTARTER LEVER.......... .................................................................. 1-19
THROTTLE GRIP ..................................................................................... 1-19
FRONT BRAKE LEVER ........................................................................... 1-19
REAR BRAKE PEDAL.............................................................................. 1-19
SIDESTAND ............................................................................................. 1-20
STARTER KNOB/IDLE SCREW .............................................................. 1-20
FUEL TANK CAP ..................................................................................... 1-20

DESCRIPTION
1-4
EAS2GC1009
DESCRIPTION
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have pur-
chased.1. Clutch lever 12. Headlight
2. Multi-function display 13. Radiator
3. Front brake lever 14. Coolant drain bolt
4. Throttle grip 15. Rear brake pedal
5. Start switch 16. Air filter
6. Radiator cap 17. Drive chain
7. Fuel tank cap 18. Shift pedal
8. Engine stop switch 19. Oil level check window
9. Taillight 20. Starter knob/idle screw
10. Fuel tank 21. Front fork
11. Kickstarter lever
32
1
8
10
91 112 1376
54
15 14 21 20 19 18 17 16

CONTROL FUNCTIONS
1-18
EAS2GC1029
CONTROL FUNCTIONS
EAS2GC1030INDICATOR LIGHTS AND WARNING
LIGHTS
Fuel level warning light “ ”
This warning light comes on when the fuel level
drops below approximately 1.6 L (0.42 US gal,
0.35 Imp.gal). When this occurs, refuel as soon
as possible.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the start switch is pushed, or if the warn-
ing light remains on, have a Yamaha dealer
check the electrical circuit.
Engine trouble warning light “ ”
This warning light comes on or flashes if a prob-
lem is detected in the electrical circuit monitor-
ing the engine. If this occurs, have a Yamaha
dealer check the vehicle.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the start switch is pushed, or if the warn-
ing light remains on, have a Yamaha dealer
check the electrical circuit.
EAS2GC1031ENGINE STOP SWITCH
The engine stop switch “1” is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
After the engine stops, the multi-function dis-
play will go off and the power supply to the ECU
(Electronic Control Unit) will be cut off if the en-
gine stop switch is pushed and held.
TIP
The multi-function display will go off after one
minute if the engine stop switch is not pushed.
EAS2GC1032START SWITCH
The start switch “1” is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.
EAS2GC1033CLUTCH LEVER
The clutch lever “1” is located on the left han-
dlebar. The clutch lever disengages or engag-
es the clutch.
Pull the clutch lever toward the handlebar to
disengage the clutch, and release the lever to
engage the clutch.
1. Engine trouble warning light “ ”
2. Fuel level warning light “ ”
12

STARTING AND BREAK-IN
1-28
EAS2GC1048
STARTING AND BREAK-IN
EAS2GC1049FUEL
Always use the recommended fuel as stated
below. Also, be sure to use new gasoline the
day of a race.
ECA
NOTICE
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to the engine internal parts such as valves,
piston rings, and exhaust system, etc.
TIP
Your Yamaha engine has been designed to use
premium unleaded gasoline with a pump oc-
tane number [(R+M)/2] of 91 or higher, or a re-
search octane number of 95 or higher. If
knocking (or pinging) occurs, use a gasoline of
a different brand.
EWA
WARNING
• For refueling, be sure to stop the engine and use enough care not to spill any fuel.
Also be sure to avoid refueling close to a
fire.
• Refuel after the engine, exhaust pipe, etc.
have cooled off.
Gasohol (For USA and Canada)
There are two types of gasohol: gasohol con-
taining ethanol and that containing methanol.
Gasohol containing ethanol can be used if the
ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by
Yamaha because it can cause damage to the
fuel system or vehicle performance problems.
EAS2GC1050HANDLING NOTEEWA
WARNING
Never start or run the engine in a closed ar-
ea. The exhaust fumes are poisonous; they
can cause loss of consciousness and death
in a very short time. Always operate the ma-
chine in a well-ventilated area.
ECA
NOTICE
• Unlike a two-stroke engine, this engine cannot be kick started when the throttle is
open because the kickstarter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the engine
to start.
• Before starting the machine, perform the
checks in the pre-operation check list.
EAS2GC1051AIR FILTER MAINTENANCE
According to “CLEANING THE AIR FILTER
ELEMENT” section in the CHAPTER 3, apply
the Yamaha foam air filter oil or other quality
foam air filter oil to the element. (Excess oil in
the element may adversely affect engine start-
ing.)
EAS2GC1052STARTING A COLD ENGINEECA
NOTICE
For maximum engine life, never accelerate
hard when the engine is cold!
In order for the ignition circuit cut-off system to
enable starting, one of the following conditions
must be met:
• The transmission is in the neutral position.
• The transmission is in gear with the clutch le- ver pulled.
1. Pull the starter knob/idle screw “1” to its full length.
TIP
When the ambient temperature is 15°C (59°F)
or below, use the starter knob/idle screw.
2. Completely close the throttle.
3. Start the engine by pushing the start switch.If the engine fails to start when using the
start switch, release it, wait a few seconds,
and then try again.
Each starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 10 seconds on
any one attempt. If the engine does not start
with the starter motor, try using the kickstart-
er.
Recommended fuel
Premium unleaded gasoline
only
Fuel tank capacity 7.5 L (2.0 US gal, 1.7 lmp.gal)
Fuel reserve amount 2.0 L (0.5 US gal, 0.4 Imp.gal)
1

STARTING AND BREAK-IN
1-29
ECA
NOTICE
If the starter motor will not turn when the
start switch is pushed, stop pushing it im-
mediately in order to avoid placing extra
load on the starter motor, and start the en-
gine by using the kickstarter.
TIP
If the engine fails to start, push the engine stop
switch and give the kickstarter 10 to 20 slow
kicks at full throttle in order to clear the engine
of the rich air-fuel mixture retained in it.
4. When the engine starts running, warm this up one or two minutes at a steady speed (of
3000 to 5000 r/min), and then return the
starter knob/idle screw to its original posi-
tion.
EWA
WARNING
Since exhaust gas contains harmful ingre-
dients, do not start or warm it up at an ill-
ventilated place or a closed narrow place.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
5. To stop the engine, push the engine stop switch “1”.
TIP
Continue pushing the engine stop switch till the
engine comes to a full stop. Starting with the kickstarter
When using the kickstarter to start the engine,
follow the procedures as described below.
1. Fold out the kickstarter lever, push it down
lightly with your foot until resistance is felt.
2. With the throttle fully closed,push the kick- starter down lightly until the gears engage,
and then push it down smoothly but forceful-
ly.
EWA
WARNING
Do not open the throttle while kicking the
kickstarter lever. Otherwise, the kickstarter
lever may kick back.
TIP
If the engine fails to start, push the engine stop
switch and give the kickstarter 10 to 20 slow
kicks at full throttle in order to clear the engine
of the rich air-fuel mixture retained in it.

STARTING AND BREAK-IN
1-30
EAS2GC1053STARTING A WARM ENGINE
Follow the same procedure as for starting a
cold engine with the exception that the starter is
not required when the engine is warm.
TIP
If it fails to start, fully open the throttle grip and
give 10 to 20 slow kicks to clear the engine of
the rich air-fuel mixture retained in it.
EAS2GC1054BREAK-IN PROCEDURES
A break-in is important so that rotating portion,
sliding surfaces, and mounted areas may fit
one another, and that the rider may become ac-
customed to the machine.
ECA
NOTICE
Before running, do maintenance on the air
filter element.
Refer to “CLEANING THE AIR FILTER ELE-
MENT” on page 3-14.
1. After warming up the engine, drive it for about 20 minutes at a throttle opening of 1/2
or less.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
2. Make a pit stop, and check mounted areas
for looseness, oil leaks, or other problems.
3. Then, drive it for about 40 minutes at a throt- tle opening of 3/4 or less.
4. Make a pit stop again, and thoroughly check mounted areas for looseness, oil leaks, or
other problems. Thorough checks and ad-
justments are required in particular for
stretch of cables, free play of the brake,
stretch of the drive chain, looseness of the
spoke, and so on.
ECA
NOTICE
After a break-in or after each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them. (Refer to “TORQUE-CHECK
POINTS” on page 1-32.)
Also when the following parts are replaced,
a break-in is required.
• Cylinder and Crankshaft: A break-in is re-quired for about an hour.
• Piston, Piston ring, Valve, Camshaft, and
Gear: A break-in is required for about 30
minutes at a throttle opening of 1/2 or less.
Observe the condition of the engine careful-
ly during a break-in.
For checkpoints for a break-in, see “MAIN-
TENANCE AFTER BREAK-IN”. If any prob-
lem is found, immediately stop the engine
and make a checkup.

ENGINE
3-16
3. Check:• Tightening torques
4. Install: • Exhaust pipe protector
EAS2GC1095CHECKING THE FUEL LINE
1. Remove:• Seat
• Side cover (left/right)
• Air scoop (left/right)Refer to “GENERAL CHASSIS” on page 5-
1.
• Fuel tank Refer to “FUEL TANK” on page 8-1.
2. Check:
• Fuel hose “1”Crack/damage  Replace.
Loose connection  Connect properly. 3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 8-1.
• Air scoop (left/right)
• Seat
• Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-
1.
EAS2GC1096CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle upright on a level surface.
2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait
about 1 minute.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
3. Check:
• Oil levelMake sure that the engine oil level is above
the minimum level mark “a” shown for the oil
level check window “1”, and that the engine
oil does not come out by removing the oil
check bolt “2”.
The minimum level mark “a” or below  Add
the engine oil until its level exceeds the min-
imum level mark “a”.
Engine oil coming out of the oil check bolt 
Drain it until its last drop is out.
ECA33DD018
Exhaust pipe bolt 1 and nut “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe 1 and exhaust pipe
2 bolt “2” 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Exhaust pipe 2 and silencer bolt
“3” 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer and silencer bracket bolt
“4” 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe protector screw 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
T R..
2
1
4
3
T R..
1
12
a

ENGINE
3-19
EAS2GC1098ADJUSTING THE ENGINE IDLING SPEED
TIP
• Because the air pressure is lower at high alti-tudes, the air-fuel mixture will become richer.
If the idling speed is low, turn the starter knob/
idle screw a few clicks counterclockwise to in-
crease the speed before the adjustment.
• Before adjusting the engine idling speed, make sure that the air filter element is not
clogged, the engine compression is proper,
and the throttle grip free play is proper.
• Adjust the engine idling speed with the starter
knob/idle screw pushed in completely.
1. Start the engine, and warm this up until the oil has reached the specified temperature.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
2. Attach the pocket tester with temperature probe “1” to the oil drain bolt.
3. Install: • Digital tachometer
TIP
Get the high tension cord “1” of the ignition coil
pinched in the detector “a” of the digital tachom-
eter.
4. Measure:• Engine idling speed
Out of specification  Regulate.
5. Adjust: • Engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the starter knob/idle screw “1” in the di- rection of “a” or “b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Oil temperature70–80 °C (158–176 °F)
Digital tachometer 90890-06760
Digital tachometer YU-39951-B
1
Engine idling speed 1900–2100 r/min
Direction “a” Engine idling speed  De-
creases.
Direction “b” Engine idling speed  In-
creases.
1
1
a
a
1
b
a