2016 YAMAHA WR 450F checking oil

3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................. 3-1
INTRODUCTION ........................................................................................ 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ....................... .......................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 3-2
MAINTENANCE INTERVALS FOR COMPETITION USE ......................... 3-4
PRE-OPERATION INSPECTION AND MAINTENANCE ................................. 3-9
GENERAL INSPECTION AND MAINTENANCE........................................ 3-9
ENGINE .......................................................................................................... 3-10
CHECKING THE COOLANT LEVEL ........................................................ 3-10
CHECKING THE COOLING SYSTEM ..................................................... 3-10
CHANGING THE COOLANT.................................................................... 3-10
CHECKING THE RADIATOR CAP .......................................................... 3-11
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ....... 3-11
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-12
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-13
LUBRICATING THE THROTTLE CABLE ................................................ 3-14
CLEANING THE AIR FILTER ELEMENT................................................. 3-14
CHECKING THE THROTTLE BODY JOINT ............................................ 3-15
CHECKING THE BREATHER HOSES .................................................... 3-15
CHECKING THE EXHAUST SYSTEM............................. ........................ 3-15
CHECKING THE FUEL LINE ................................................................... 3-16
CHECKING THE ENGINE OIL LEVEL............................. ........................ 3-16
CHANGING THE ENGINE OIL ................................................................ 3-17
ADJUSTING THE ENGINE IDLING SPEED ......... ................................... 3-19
ADJUSTING THE VALVE CLEARANCE ................................................. 3-20
CLEANING THE SPARK ARRESTER ..................................................... 3-24
CHASSIS ........................................................................................................ 3-25
BLEEDING THE BRAKE SYST EM .......................................................... 3-25
CHECKING THE BRAKE HOSE .............................................................. 3-26
ADJUSTING THE FRONT BRAKE .......................................................... 3-26
ADJUSTING THE REAR BRAKE ............................................................. 3-27
CHECKING THE FRONT BR AKE PADS ................................................. 3-27
CHECKING THE REAR BRAKE PADS ........................... ........................ 3-29
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-30
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-30
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-31
CHECKING THE FRONT FORK LEGS ................................................... 3-31
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-32
CLEANING THE FRONT FORK OI L SEAL AND DUST SEAL ................ 3-32
AIR BLEEDING FROM FRONT FORK .................................................... 3-32
ADJUSTING THE FRONT FORK LEGS .................................................. 3-33
CHECKING THE SWINGARM OPERATION ........................................... 3-34
CHECKING THE REAR SUSPENSION ................................................... 3-34

ENGINE
3-15
NOTICE
Do not twist the element when squeezing
the element.
4. Check:• Air filter element
Damage  Replace.
5. Yamaha foam air filter oil or other quality foam air filter oil.
TIP
Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:• Air filter guide “1” (to the air filter element)
• Air filter element “2”
• Air filter mounting bolt “3”
7. Install: • Air filter case cover “1”
TIP
Align the air filter case cover groove “a” with the
air filter case edge “b”. 8. Install:
• Fuel tank cap cover
EAS2GC1092CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body jointRefer to “CHECKING THE THROTTLE
BODY JOINT” on page 8-10.
EAS2GC1093CHECKING THE BREATHER HOSES
1. Check:• Breather hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
ECA
NOTICE
Make sure the cylinder head breather hose
is routed correctly.
EAS2GC1094CHECKING THE EXHAUST SYSTEM
1. Remove:
• Exhaust pipe protector
2. Check: • Exhaust pipe 1
• Exhaust pipe 2
• SilencerCrack/damage  Replace.
Refer to “ENGINE REMOVAL” on page 6-1.
• Exhaust gas Leaks  Replace the gasket.
Refer to “ENGINE REMOVAL” on page 6-1.
Oil application quantify
50 g
Air filter mounting bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
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31
2
a
b
1
1

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®
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2
1
4
3
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1
12
a

ENGINE
3-18
c. Replace the O-ring “2”.
d. Install the oil strainer.
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6. Install:•Gasket
• Drain bolt
7. Pour the specified amount of engine oil into the oil filler cap hole.
8. Install: • Oil filler cap
9. Check: • Oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-16. 10.Check:
• Engine oil pressure
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a. Slightly loosen the oil pressure check bolt “1”.
EWA
WARNING
When the engine is started with the check
bolt removed, oil will spout; therefore, al-
ways loosen it before the checkup.
b. Start the engine and keep it idling until oil starts to seep from the oil pressure check
bolt.
EWA
WARNING
Always keep the engine idling speed during
the checkup without increasing the engine
speed.
ECA
NOTICE
If no engine oil seeps out after one minute,
immediately turn the engine off so it will not
seize.
c. If no engine oil seeps out, check the engine oil for leaks, and t he engine oil passage and
the oil pump for damage.
d. Check the oil pressure again.
e. Tighten the oil pressure check bolt.
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Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drain bolt 20 Nm (2.0 m·kgf, 14 ft·lbf)
Engine oil quantity 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)
Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt)
1
2New
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New
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Oil pressure check bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
T R..

CHASSIS
3-31
• When refilling, be careful that water does not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
EAS2GC1110ADJUSTING THE DRIVE CHAIN SLACKECA
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Shift the transmission into the neutral posi-
tion.
3. Pull the drive chain up above the drive chain guide installation bolt with a force of about
50 N (5.0 kgf, 36 lbf).
4. Check: • Drive chain slack “a”
Out of specification  Regulate.
TIP
Measure drive chain slack between the drive
chain guide and the bottom of the chain as
shown. 5. Adjust:
• Drive chain slack
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a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn the adjusting bolt “3” in direction “a” or “b” until the specified drive chain slack is ob-
tained.
TIP
• To maintain the proper wheel alignment, ad-just both sides evenly.
• Push the rear wheel forward to make sure that
there is no clearance between the swingarm
end plates and the ends of the swingarm.
d. Tighten the locknut.
e. Tighten the wheel axle nut.
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EAS2GC1111CHECKING THE FRONT FORK LEGS
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check: • Inner tubeDamage/scratches  Replace.
• Front fork leg (s) Oil leaks between inner tube and outer tube
 Replace the oil seal.
Drive chain slack (on a suitable
stand)
50.0–60.0 mm (1.97–2.36 in)
a
Direction “a”The drive chain slack decreases.
Direction “b” The drive chain slack increases.
Locknut21 Nm (2.1 m·kgf, 15 ft·lbf)
Wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf)
1
32
a
b
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CHASSIS
3-32
3. Hold the vehicle upright and apply the front brake.
4. Check:
• Front fork operationPush down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation  Correct or replace.
Refer to “FRONT FORK” on page 5-40.
EAS2GC1112CHECKING THE FRONT FORK PROTEC-
TOR GUIDE
1. Check:
• Protector guide “1”Out of specification  Replace.
TIP
The protector guide reaches the limit of its use
when it is worn down to the same height “a” as
of the outer tube circumference.
EAS2GC1113CLEANING THE FRONT FORK OIL SEAL
AND DUST SEAL
1. Remove:
•Protector
• Dust seal “1”
ECA
NOTICE
Be careful not to damage the dust seal and
the inner tube by a driver. 2. Clean:
• Dust seal “a”
• Oil seal “b”
TIP
• Clean the dust seal and oil seal after every
run.
• Apply lithium-soap-based grease on the inner
tube.
EAS2GC1114AIR BLEEDING FROM FRONT FORK
TIP
If the front fork initial movement feels stiff dur-
ing a run, relieve the front fork internal pres-
sure.
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove the air bleed screw “1” and release the internal pressure from the front fork.
1
a
1
LS
a
b

CHASSIS
3-34
EAS2GC1116CHECKING THE SWINGARM OPERATION
1. Check:• Swingarm smooth action
• Swingarm free playRefer to “SWINGARM” on page 5-65.
EAS2GC1117CHECKING THE REAR SUSPENSION
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:• Rear shock absorber assemblyGas leaks/oil leaks  Replace the rear
shock absorber assembly.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
3. Check: • Rear shock absorber assembly smooth ac-tion
• Rear suspension link smooth action Sit astride the seat and shake your body up
and down several times to check whether
the rear shock absorber assembly operates
smoothly.
Unsmooth operation  Correct or replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
EAS2GC1118ADJUSTING THE REAR SHOCK ABSORB-
ER ASSEMBLY
Use a suitable stand to raise the rear wheel off
the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over. Spring preload
ECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Remove:
• Rear frameRefer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
2. Adjust: • Spring preload
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a. Loosen the locknut “1”.
b. Loosen the adjuster “2” until there is some clearance between the spring and the ad-
juster.
c. Measure the spring free length “a”.
d. Turn the adjuster in the direction of “b” or “c” to make an adjustment.
Direction “b”Spring preload is increased (suspen-
sion is harder).
Direction “c” Spring preload is decreased (suspen-
sion is softer).
Spring preload adjusting positionsMinimum Position in which the spring is
turned in 1.5 mm (0.06 in) from
its free length.
Standard Position in which the spring is
turned in 12 mm (0.47 in) from its
free length.
Maximum Position in which the spring is
turned in 18 mm (0.71 in) from its
free length.

CHASSIS
3-38
c. Turn the front fork to the right and left a few times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly,
remove the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 5-53.
d. Loosen the ring nut fully turn and then tight- en it to specification with a steering nut
wrench.
EWA
WARNING
Do not overtighten the lower ring nut.
e. Check the steering head for looseness or binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 5-53.
f. Install the washer “1”.
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5. Install: • Upper bracketRefer to “STEERING HEAD” on page 5-53.
• Handlebar
Refer to “HANDLEBAR” on page 5-33.
EAS2GC1124CHECKING AND LUBRICATING THE CA-
BLES
The following procedure applies to all of the in-
ner and outer cables.
EWA
WARNING
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner ca-
bles as soon as possible.
1. Check:• Outer cableDamage  Replace.
2. Check: • Cable operationRough movement  Lubricate.
TIP
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
EAS2GC1125LUBRICATING THE LEVERS
1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
•Brake lever
• Clutch lever
EAS2GC1126LUBRICATING THE PEDAL
1. Lubricate the pivoting point and metal-to-
metal moving parts of the pedal.
Steering nut wrench
90890-01403
Exhaust flange nut wrench YU-A9472
Ring nut (initial tightening torque) 38 Nm (3.8 m·kgf, 27 ft·lbf)
Ring nut (final tightening torque) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
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1
Recommended lubricantEngine oil or a suitable cable lu-
bricant
Recommended lubricant Silicone grease
Recommended lubricant Lithium-soap-based grease
Recommended lubricant Lithium-soap-based grease