2016 YAMAHA WR 450F Owners Manual

PERIODIC MAINTENANCE
3-7
BRAKESAdjust lever posi-
tion and pedal
height
Lubricate pivot
point
Check brake disc
surface
Check fluid level
and leakage
Retighten brake
disc bolts, caliper
bolts, master cylin-
der bolts and union
bolts
Replace pads
Replace brake flu-
id Every one year
FRONT FORKS Inspect and adjust
Replace oil Yamaha Suspension Oil S1
Replace oil seal
FRONT FORK OIL
SEAL AND DUST
SEAL Clean and lube Lithium-soap-based grease
PROTECTOR
GUIDE
Replace
REAR SHOCK AB-
SORBER (After
rain
ride)
Inspect and adjust
Lube Molybdenum disulfide grease
Retighten
DRIVE CHAIN
GUARD AND ROLL-
ERS
Inspect
DRIVE CHAIN
STOPPER Inspect ITEM
After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks

PERIODIC MAINTENANCE
3-8
SWINGARMInspect, lube and
retighten Molybdenum disulfide grease
RELAY ARM, CON-
NECTING ROD Inspect, lube and
retighten Molybdenum disulfide grease
SIDESTAND Lubricate Lithium-soap-based grease
STEERING HEAD Inspect free play
and retighten
Clean and lube Lithium-soap-based grease
Replace bearing
TIRE, WHEELS
Inspect air pres-
sure, wheel run-
out, tire wear and
spoke looseness
Retighten sprocket
bolt
Inspect bearings
Replace bearings
Lubricate Lithium-soap-based grease
THROTTLE, CON-
TROL CABLE
Check routing and
connection
Lubricate Yamaha cable lube or SAE
10W-30 motor oil
ITEM
After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks

PRE-OPERATION INSPECTION AND MAINTENANCE
3-9
EAS2GC1079
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAS2GC1080GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
Coolant Check that coolant is filled up to the radiator cap.
Check the cooling system for leakage. 3-10 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage. 1-28
Engine oil Check that the oil level is correct. Check the crank-
case and oil line for leakage. 3-16 – 18
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly. 3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary. 3-13 – 14
Brakes Check the play of front brake and effect of front and
rear brake. 3-25 – 31
Drive chain Check drive chain slack and alignment. Check that
the drive chain is lubricated properly. 3-31
5-69 – 70
Wheels Check for excessive wear and tire pressure. Check
for loose spokes and have no excessive play. 3-36 – 37
Steering Check that the handlebar can be turned smoothly and
have no excessive play. 3-37 – 38
Front forks and rear
shock absorber Check that they operate smoothly and there is no oil
leakage.
3-31 – 36
Cables (wires) Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and
has no cracks. 3-15 – 16
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is
not loose. 5-10 – 11
Lubrication Check for smooth operation. Lubricate if necessary. 3-14
3-38 – 39
Bolts and nuts Check the chassis and engine for loose bolts and
nuts. 1-32 – 33
Lead connectors Check that the AC magneto, ECU and ignition coil are
connected tightly. 1-9 – 12
Settings Is the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?
4-1 – 8

ENGINE
3-10
EAS2GC1081
ENGINE
EAS2GC1082CHECKING THE COOLANT LEVELEWA
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
1. Stand the vehicle upright on a level surface.
2. Remove:• Radiator cap “1”
3. Check: • Coolant levelMaximum level “a” or below  Add coolant
up to the maximum level.
ECA
NOTICE
• Adding water instead of coolant lowers the
antifreeze content. If, therefore, water is
used instead of coolant, check, and if nec-
essary, adjust the antifreeze concentra-
tion.
• Use only distilled water. However, if dis- tilled water is not available, soft water may
be used.
4. Start the engine, warm this up for 3 minutes, and then stop it.
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. Check:
• Coolant level
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
EAS2GC1083CHECKING THE COOLING SYSTEM
1. Remove:• Seat
• Side cover (left/right)
• Air scoop (left/right)Refer to “GENERAL CHASSIS” on page 5-
1.
• Air filter case cover Refer to “THROTTLE BODY” on page 8-7.
2. Check:
• Radiator
• Radiator hosesCrack/damage  Replace.
Refer to “RADIATOR” on page 7-1.
3. Install: • Air filter case cover
Refer to “THROTTLE BODY” on page 8-7.
• Air scoop (left/right)
• Seat
• Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-
1.
EAS2GC1084CHANGING THE COOLANTEWA
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
1. Place a container under the engine.
2. Remove:• Coolant drain bolt “1”
1. Radiator
1

ENGINE
3-11
3. Remove:• Radiator capSlowly loosen the radiator cap to drain cool-
ant.
TIP
When the radiator cap is loosened, coolant will
gush out transversely; therefore, bring the con-
tainer near to the outlet.
4. Thoroughly flush the cooling system with
clean tap water.
5. Install:
• Copper washer
• Coolant drain bolt
6. Pour coolant.
EWA
WARNING
• If coolant splashes in your eyes, thorough- ly wash them with water and consult a
doctor.
• If coolant splashes on your clothes, quick-
ly wash it away with water and then with
soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA
NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water
is used instead of coolant check, and if
necessary, correct the antifreeze concen-
tration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
7. Install:• Radiator cap 8. Start the engine, warm this up for 3 minutes,
stop it, and then wait for it to cool down.
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.
9. Check:• Coolant levelRefer to “CHECKING THE COOLANT LEV-
EL” on page 3-10.
EAS2GC1085CHECKING THE RADIATOR CAP
1. Check:• Seal (radiator cap) “1”
• Valve and valve seat “2”
Crack/damage  Replace.
Exist fur deposits  Clean or replace.
EAS2GC1086CHECKING THE RADIATOR CAP VALVE
OPENING PRESSURE
1. Check:
• Radiator cap valve opening pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester adapter “2” and the radiator cap tester “3” to the radiator cap
“1,” and activate the tester to check whether
it can stay for 5 to 10 seconds within stan-
dard pressure values.
TIP
Before attaching the cap to the tester, apply
water to its sealing surface.
No stay  Replace.
Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Recommended coolant High quality ethylene glycol
anti-freeze containing anti-cor-
rosion for aluminum engine
Radiator (including all routes) 1.03 L (1.09 US qt, 0.91 Imp.qt)
Coolant mixing ratio 1:1 (Coolant:Water)
New
T R..
Radiator cap valve opening pres-
sure 107.9–137.3 kPa (1.08–1.37 kg/
cm
2,15.6–19.9 psi)

ENGINE
3-12
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EAS2GC1087CHECKING THE COOLANT CIRCULATORY
SYSTEM FOR LEAKS
1. Check:• Coolant level
2. Install: • Radiator cap tester “1”
• Adapter “2”
3. Activate the tester to apply the test pressure.
ECA
NOTICE
• Do not apply such a high pressure as ex- ceeds the test pressure.
• Make sure that a checkup after the cylin-
der head gasket is replaced is made after 3
minutes of warm-up.
• Make sure that coolant is filled up to the
upper level beforehand.
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.
4. Check:
• Pressure valueNo stay for 5 to 10 seconds at the test pres-
sure value  Correct.
• Radiator
• Radiator hose connections Coolant leaks  Correct or replace.
• Radiator hoses Bulges  Replace
EWA
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
EAS2GC1088ADJUSTING THE CLUTCH LEVER FREE
PLAY
1. Check:
• Clutch lever free play “a”Out of specification  Regulate.
Radiator cap tester
90890-01325
Mityvac cooling system tester kit YU-24460-A
Radiator cap tester adapter 90890-01352
Pressure tester adapter YU-33984
Radiator cap tester 90890-01325
Mityvac cooling system tester kit YU-24460-A
Radiator cap tester adapter 90890-01352
Pressure tester adapter YU-33984
Test pressure value 196 kPa (1.96 kg/cm
2, 27.9 psi)
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)

ENGINE
3-13
2. Adjust:• Clutch lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Turn the adjuster “1” in direction “a” or “b”
until the specified clutch lever free play is ob-
tained.
TIP
If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
clutch cable side.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Clutch cable side
a. Slide the clutch cable cover.
b. Loosen the locknut “1”.
c. Turn the adjuster “2” in direction “a” or “b” until the specified clutch lever free play is ob-
tained.
d. Tighten the locknut “1”.
e. Return the clutch cable cover to its original position.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1089ADJUSTING THE THROTTLE GRIP FREE
PLAY
TIP
Prior to adjusting throttle grip free play, the en-
gine idling speed should be adjusted.
1. Check:• Throttle grip free play “a”Out of specification  Regulate.
2. Adjust: • Throttle grip free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjuster “2” until the specified free
play is obtained.
c. Tighten the locknut.
EWA
WARNING
After adjusting the throttle grip free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.
Direction “a”
Clutch lever free play is increased.
Direction “b” Clutch lever free play is decreased.
Direction “a” Clutch lever free play is increased.
Direction “b” Clutch lever free play is decreased.
Locknut4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
a
b
1
T R..
Throttle grip free play
3.0–6.0 mm (0.12–0.24 in)
Direction “a” Throttle grip free play is increased.
Direction “b” Throttle grip free play is decreased.
1
2 a
b

ENGINE
3-14
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1090LUBRICATING THE THROTTLE CABLE
1. Remove:• Cover (throttle cable cap) “1”
• Cover (grip cap) “2”
• Throttle grip cap “3”
2. Lubricate: • Throttle cable end “a”
3. Install: • Throttle grip cap
• Screw (throttle grip cap) 4. Install:
• Cover (grip cap)
• Cover (throttle cable cap)
EWA
WARNING
Check that the throttle grip moves smooth-
ly. If this does not move smoothly, correct
the installed positions.
EAS2GC1091CLEANING THE AIR FILTER ELEMENT
1. Remove:• Fuel tank cap cover “1”Refer to “FUEL TANK CAP” on page 1-20.
• Air filter case cover “2”
TIP
Loosen the quick fastener screw “3” and re-
move the air filter case cover.
2. Remove:
• Air filter mounting bolt “1”
• Air filter element “2”
• Air filter guide “3” (from the air filter element)
3. Wash: • Air filter element
EWA
WARNING
Do not use gasoline or organic (acid/alka-
line) volatile oil for washing.
TIP
After washing the element with air filter cleaner
or kerosene, squeeze and dry it completely.
ECA
Recommended lubricantLithium-soap-based grease
Screw (throttle grip cap) 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
1
2
b
a
T R..
1
2
3
3
3
13
2