2016 YAMAHA WR 450F Spark plug cap

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

MOTORCYCLE CARE AND STORAGE
1-34
EAS2GC1058
MOTORCYCLE CARE AND STOR-
AGE
EAS2GC1059CARE
While the open design of a motorcycle reveals
the attractiveness of the technology, it also
makes it more vulnerable. Rust and corrosion
can develop even if high-quality components
are used. A rusty exhaust pipe may go unno-
ticed on a car, however, it detracts from the
overall appearance of a motorcycle. Frequent
and proper care does not only comply with the
terms of the warranty, but it will also keep your
motorcycle looking good, extend its life and op-
timize its performance.
Before cleaning
1. Cover the muffler outlet with a plastic bag af-ter the engine has cooled down.
2. Make sure that all caps and covers as well as all electrical coup lers and connectors, in-
cluding the spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt, like oil
burnt onto the crankcase, with a degreasing
agent and a brush, but never apply such
products onto seals, gaskets, sprockets, the
drive chain and wheel axles. Always rinse
the dirt and degreaser off with water.
Cleaning
ECA
NOTICE
• Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such prod-
ucts are used on hard-to-remove dirt, do
not leave the cleaner on the affected area
any longer than instructed. Also, thor-
oughly rinse the area off with water, imme-
diately dry it, and then apply a corrosion
protection spray.
• Improper cleaning can damage plastic parts (such as cowlings, panels, wind-
shields, headlight lenses, meter lenses,
etc.) and the mufflers. Use only a soft,
clean cloth or sponge with water to clean
plastic. However, if the plastic parts can-
not be thoroughly cleaned with water, di-
luted mild detergent with water may be
used. Be sure to rinse off any detergent
residue using plenty of water, as it is
harmful to plastic parts. • Do not use any harsh chemical products
on plastic parts. Be sure to avoid using
cloths or sponges which have been in con-
tact with strong or abrasive cleaning prod-
ucts, solvent or thinner, fuel (gasoline),
rust removers or inhibitors, brake fluid,
antifreeze or electrolyte.
• Do not use high-pressure washers or steam-jet cleaners since they cause water
seepage and deterioration in the following
areas: seals (of wheel and swingarm bear-
ings, fork and brakes), electric compo-
nents (couplers, connectors, instruments,
switches and lights), breather hoses and
vents.
• For motorcycles equipped with a wind-
shield: Do not use strong cleaners or hard
sponges as they will cause dulling or
scratching. Some cleaning compounds for
plastic may leave scratches on the wind-
shield. Test the product on a small hidden
part of the windshield to make sure that it
does not leave any marks. If the wind-
shield is scratched, use a quality plastic
polishing compound after washing.
After normal use
Remove dirt with warm water, a mild detergent,
and a soft, clean sponge, and then rinse thor-
oughly with clean water. Use a toothbrush or
bottlebrush for hard-to-reach areas. Stubborn
dirt and insects will come off more easily if the
area is covered with a wet cloth for a few min-
utes before cleaning.
After riding in the rain, near the sea or on salt-
sprayed roads
Since sea salt or salt sprayed on roads during
winter are extremely corrosive in combination
with water, carry out the following steps after
each ride in the rain, near the sea or on salt-
sprayed roads.
TIP
Salt sprayed on roads in the winter may remain
well into spring.
1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled
down.
NOTICE: Do not use warm water since it
increases the corrosive action of the salt.

MOTORCYCLE CARE AND STORAGE
1-35
2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated,
surfaces to prevent corrosion.
After cleaning
1. Dry the motorcycle with a chamois or an ab- sorbing cloth.
2. Immediately dry the drive chain and lubri- cate it to prevent it from rusting.
3. Use a chrome polish to shine chrome, alumi-
num and stainless- st eel parts, including the
exhaust system. (Even the thermally in-
duced discoloring of stainless- steel exhaust
systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all
metal, including chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal cleaner to re- move any remaining dirt.
6. Touch up minor paint damage caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely before
storing or covering it.
EWA
WARNING
Contaminants on the brakes or tires can
cause loss of control.
• Make sure that there is no oil or wax on the brakes or tires.
• If necessary, clean the brake discs and
brake linings with a regular brake disc
cleaner or acetone, and wash the tires with
warm water and a mild detergent. Before
riding at higher speeds, test the motorcy-
cle’s braking performance and cornering
behavior.
ECA
NOTICE
• Apply spray oil and wax sparingly and make sure to wipe off any excess.
• Never apply oil or wax to any rubber and
plastic parts, but treat them with a suitable
care product.
• Avoid using abrasive polishing com-
pounds as they will wear away the paint.
TIP
• Consult a Yamaha dealer for advice on what products to use.
• Washing, rainy weather or humid climates can cause the headlight lens to fog. Turning
the headlight on for a short period of time will
help remove the moisture from the lens.
EAS2GC1060STORAGE
Short-term
Always store your motorcycle in a cool, dry
place and, if necessary, protect it against dust
with a porous cover. Be sure the engine and the
exhaust system are cool before covering the
motorcycle.
ECA
NOTICE
• Storing the motorcycle in a poorly ventilat-ed room or covering it with a tarp, while it
is still wet, will allow water and humidity to
seep in and cause rust.
• To prevent corrosion, avoid damp cellars,
stables (because of the presence of am-
monia) and areas where strong chemicals
are stored.
Long-term
Before storing your motorcycle for several
months:
1. Follow all the instructions in the “Care” sec- tion of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel tank from rust-
ing and the fuel from deteriorating.
3. Perform the following steps to protect the
cylinder, piston rings, etc. from corrosion.
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a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during the
next step.)
d. Turn the engine over several times with the
starter. (This will coat the cylinder wall with
oil.)

MOTORCYCLE CARE AND STORAGE
1-36
e. Remove the spark plug cap from the spark plug, and then install the spark plug and the
spark plug cap. WARNING! To prevent
damage or injury from sparking, make
sure to ground the spark plug electrodes
while turning the engine over.
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4. Lubricate all control cables and the pivoting points of all levers and pedals as well as of
the sidestand/ centerstand.
5. Check and, if necessary, correct the tire air
pressure, and then lift the motorcycle so that
both of its wheels are off the ground. Alter-
natively, turn the wheels a little every month
in order to prevent the tires from becoming
degraded in one spot.
6. Cover the muffler outlet with a plastic bag to
prevent moisture from entering it.
7. Remove the battery and fully charge it. Store it in a cool, dry place and charge it once a
month. Do not store the battery in an exces-
sively cold or warm place [less than 0 °C (30
°F) or more than 30 °C (90 °F)]. For more in-
formation on storing the battery, See page
9-69.
TIP
Make any necessary repairs before storing the
motorcycle.

ENGINE SPECIFICATIONS
2-2
EAS2GC1062
ENGINE SPECIFICATIONS
EngineEngine type Liquid cooled 4-stroke, DOHC
Displacement 449 cm
3
Number of cylinders Single cylinder
Bore  stroke 97.0  60.8 mm (3.82  2.39 in)
Compression ratio 12.5:1
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 7.5 L (2.0 US gal, 1.7 Imp.gal)
Fuel reserve amount 2.0 L (0.5 US gal, 0.4 Imp.gal)
Engine oilLubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-40, SAE 10W-50, SAE 15W-40, SAE 20W-40 or SAE 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard MA
Engine oil quantity
Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt)
Oil change 0.67 L (0.71 US qt, 0.59 Imp.qt)
With oil filter removal 0.69 L (0.73 US qt, 0.61 Imp.qt)
Oil filterOil filter type Paper
Bypass valve opening pressure 40.0–80.0 kPa (0.40–0.80 kgf/cm
2,
5.8–11.6 psi)
Oil pump Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clear ance 0.000–0.150 mm (0.0000–0.0059 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to -inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.17 mm (0.0067 in)
Cooling system
Radiator (including all routes) 1.03 L (1.09 US qt, 0.91 Imp.qt)
Radiator capacity 0.57 L (0.60 US qt, 0.50 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kg/cm
2,
15.6–19.9 psi)
Radiator core Width 112.6 mm (4.43 in)
Height 235.0 mm (9.25 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)Manufacturer/model NGK/CR8E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)

ELECTRICAL SPECIFICATIONS
2-10
EAS2GC1064
ELECTRICAL SPECIFICATIONS
VoltageSystem voltage 12 V
Ignition systemIgnition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min
Engine control unitModel/manufacturer 2GC0/YAMAHA (USA) (CAN) 2GC1/YAMAHA (EUR) (AUS) (NZL) (ZAF)
Ignition coilMinimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k 
Spark plug cap
Resistance 7.50–12.50 k 
Lean angle sensor output voltage
Operating angle 45 °
Output voltage up to operating angle 3.7–4.4 V
Output voltage over operating angle 0.4–1.4 V
AC magneto
Standard output 14.0 V, 160 W at 5000 r/min
Stator coil resistance 0.528–0.792  (W–W)
Rectifier/regulator
Regulator type Three-phase
No load regulated voltage 14.1–14.9 V
Rectifier capacity (DC) 35.0 A
BatteryModel YTZ7S (F)
Voltage, capacity 12 V, 6.0 Ah (10HR)
Specific gravity 1.31
Manufacturer GS YUASA
Ten hour rate charging current 0.60 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage  quantity
Headlight HS1, 35.0 W/35.0 W  1 (Hi)
Tail/brake light LED
Meter lighting EL (Electroluminescent)
Indicator light
Fuel level warning light 12 V, 1.7 W  1
Engine trouble warning light 12 V, 1.7 W  1
Electric starting system
System type Constant mesh

TIGHTENING TORQUES
2-13
EAS2GC1066ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEM Thread
size Q’ty TIGHTENING TORQUES Remarks
Camshaft cap bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt (exhaust
pipe) M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head bolt M10 4See TIP.*1
Cylinder head bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage plug (cylinder head) M8 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf) Use a
lock
washer.
Balancer nut M10 1 45 Nm (4.5 m·kgf, 33 ft·lbf) Use a
lock
washer.
Timing chain guide stopper plate
(exhaust side) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator fan bolt M6 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Water pump housing cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screw M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage cover bolt (left crank-
case cover) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
E
LT
M
LT
LT
LT

CABLE ROUTING DIAGRAM
2-36
1. Clamp
2. Throttle position sensor lead
3. Joint coupler
4. Intake air temperature sensor lead
5. Intake air pressure sensor lead
6. Wire harness
7. Injector lead
8. Injector coupler
9. Throttle body
10. Cylinder head breather hose
11. Engine ground sub-lead
12. Plate
13. Engine ground sub-lead coupler
14. Starter motor lead
15. Plastic band
16. Fuel sender coupler
17. High tension cord
18. Spark plug cap
19. Cylinder head cover
20. Fuel hose
21. Fuel sender
22. Sub-wire harness
23. Radiator breather hose
24. Radiator hose
25. Down tube
26. Starter motor cover
27. Starter motor
28. AC magneto lead
29. Clutch cable
30. Neutral switch lead
31. Radiator
32. Breather hose clamp
33. Grommet (high tension cord)
34. ECU
35. Air filter case
36. Sub-wire harness coupler
37. Engine bracket
A. Fix the wire harness, clutch switch lead and start switch lead by the plasti c clamp, and insert the
projection of the plastic clamp into the hole in the
sheet metal of the radiator.
B. Route each lead so that the leads are not pinched between the tank rail and air filter joint.
C. Insert the projection of the wire harness into the hole in the frame.
D. Pass the cylinder head breather hose between the throttle cable and engine ground sub-lead.
E. Insert the engine ground sub-lead coupler into the plate, facing inside the vehicle.
F. Connect the sub-wire harness to the wire har- ness.
G. Pass the high tension cord above the fuel hose.
H. ±10°
I. Install the spark plug cap with this facing the right
of the vehicle.
J. Push the spark plug cap home, where there shall be no gap between it and the cylinder head cover.
K. Pass the radiator breather hose between the down tubes.
L. Pass the starter motor lead under the starter mo- tor shaft.
M. Pass the sub-wire harness between the ECU and the air filter case.
N. Apply adhesive to the s lit and inside of the grom-
met, and then fix the grommet according to the
specified dimensions.
O. 50±3 mm (2.0±0.12 in)
P. Insert the coupler of the sub-wire harness into the
rib of the air filter case. Q. Clamp the starter motor lead, point the clamp
downward, and insert it into the frame.
R. Route the radiator breather hose through be- tween the radiator hose, down tube and engine
bracket.