2016 YAMAHA WR 450F clutch

TIGHTENING TORQUES
2-17
EAS2GC1067CHASSIS 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
Outer tube and upper bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Outer tube and lower bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Upper bracket and steering stem nut M24 1 145 Nm (14.5 m·kgf, 105 ft·lbf)
Upper handlebar holder bolt M8 4 28 Nm (2.8 m·kgf, 20 ft·lbf)
Lower handlebar holder nut M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Engine stop switch screw M3 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Start switch screw M4 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Lower ring nut M28 1See TIP.
Outer tube and damper assembly M51 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Inner tube and adjuster M22 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Damper assembly and base valve M42 2 28 Nm (2.8 m·kgf, 20 ft·lbf)
Damper assembly adjuster M12 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
Bleed screw (front fork) and base
valve M5 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Front fork protector bolt M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fork protector and brake hose
holder nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle grip cap screw M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever holder bolt M6 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever nut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front brake master cylinder holder
bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake master cylinder reser-
voir cap screw M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Front brake lever pivot bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever pivot nut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever position locknut M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front brake hose holder and lower
bracket bolt M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front brake caliper bolt M8 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Front brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front wheel axle nut M16 1 90 Nm (9.0 m·kgf, 65 ft·lbf)
Front wheel axle pinch bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
LT

LUBRICATION POINTS AND LUBRICANT TYPES
2-21
EAS2GC1068
LUBRICATION POINTS AND LUBRICANT TYPES
EAS2GC1069ENGINE
Lubrication point Lubricant types
Oil seal lips
Bearing
O-ring
Camshaft cap bolt threads and contacting surface
Cylinder head bolt threads, seats, washers
Valve stems
Valve stem ends
Valve lifter outer surface
Camshaft lobe and journal
Valve lifter top surface
Crankshaft journal
Crankshaft big end thrust surfaces
Piston outer surface
Piston pin outer surface
Decompression system moving parts
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil passage gasket
Oil pump shaft
Kick gear and ratchet wheel
Kick shaft
Kick idle gear inner surface
Ratchet wheel and ratchet wheel guide contacting portion
Primary drive gear nut threads and contacting surface
Primary driven gear inner surface and end surface
Clutch push rod washer
Clutch push rod 1 outer surface
Clutch push rod 1 thrust surface
Clutch push rod 2 outer surface
Push lever shaft outer surface
Transmission gear inner surface (wheel and pinion) and collar
Transmission gears (shift fork groove)
Shift cam grooves
Shift fork and shift fork guide outer surface
Shift shaft and collar
Shift lever assembly moving parts
Damper assembly shaft, thrust surfaces, washers
LS
E
LS
E
M
M
M
E
M
E
M
E
E
M
E
E
E
LS
E
M
E
E
M
E
E
E
E
E
E
E
M
E
E
E
E
E
E

LUBRICATION POINTS AND LUBRICANT TYPES
2-22
EAS2GC1070CHASSISStarter idle gear inner surface, thrust surfaces
Starter clutch drive gear inner surface, thrust surfaces
Cylinder head cover gasket
Yamaha bond
No.1215
(Three bond No.1215®)
Crankcase mating surface Yamaha bond
No.1215
(Three bond No.1215®)
Stator assembly lead grommet Yamaha bond
No.1215
(Three bond No.1215®)
Lubrication point Lubricant types
Upper bearings (steering head)
Upper bearings and bearing race cover (steering head)
Lower bearings and oil seal lip (steering head)
Steering stem threads and nut contacting surface
Pivot shaft bearing
Swingarm pivot portion (collar side surface and thrust bearing)
Swingarm pivot portion (collar outer surface)
Swingarm pivot portion (oil seal lip)
Pivot shaft outer surface
Relay arm bearing and oil seal lip
Relay arm thrust washer surface (both sides)
Relay arm collar outer surface and bolt outer surface
Relay arm bolt threads (swingarm side)
Connecting arm bearing and oil seal lip
Connecting arm collar outer surface and bolt outer surface
Rear shock absorber assembly collar outer surface and dust seal lip (upper
side)
Rear shock absorber assembly bearing and dust seal lip (lower side)
Brake pedal pivot portion (O-ring and bolt outer surface)
Front wheel oil seal lip
Front wheel axle outer surface
Rear wheel oil seal lip
Rear wheel axle outer surface
Sidestand pivot portion and collar outer surface
Push rod contacting portion (front brake master cylinder)
Front brake lever bolt outer surface Lubrication point
Lubricant types
E
E
LS
LS
LS
LS
M
M
M
M
M
M
M
M
M
M
M
M
M
LS
LS
LS
LS
LS
LS
S
S

LUBRICATION POINTS AND LUBRICANT TYPES
2-23
Clutch lever sliding surface and bolt outer surface
Clutch lever adjuster rubber lip
Clutch cable end (clutch lever side)
Tube guide (throttle grip) inner surface and throttle cable end
Front brake caliper piston
Front brake caliper piston seal
Front brake caliper dust seal
Front brake caliper piston outer surface
Front brake caliper pin bolt and boot
Front brake master cylinder push rod end
Front brake master cylinder kit
Rear brake caliper piston
Rear brake caliper piston seal
Rear brake caliper dust seal
Rear brake caliper piston outer surface
Rear brake caliper pin bolt and boot
Rear brake master cylinder push rod end
Rear brake master cylinder kit Lubrication point Lubricant typesLS
LS
LS
LS
S
S
S
S
S
S
S
S

CABLE ROUTING DIAGRAM
2-34
1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Engine stop switch lead
5. Coupler for connecting optional part
6. Engine stop switch coupler
7. Rectifier/regulator coupler
8. AC magneto lead
9. Starter knob/idle screw
10. Engine ground sub-lead
11. Starter motor lead
12. Radiator fan fuse
13. Taillight lead
14. Headlight relay (yellow tape)
15. Starting circuit cut-off relay (no identification tape)
16. Diode
17. Holder plate
18. Left of the vehicle:radiator fan motor relay (blue tape)
Right of the vehicle:main relay (red tape)
19. Neutral switch lead
20. Front engine bracket
21. Plastic locking tie
22. Radiator hose
23. Neutral switch coupler
24. Crankshaft position sensor coupler
25. Tension arm
26. Wire harness
27. Tank rail
28. Rectifier/regulator
29. Rectifier/regulator bracket
30. Rear frame
31. Side cover 5
32. Crankcase cover
33. Crankcase
34. Lead holder
35. Frame
36. Engine ground sub-lead coupler
A. Pass the engine stop switch lead between the frame and the cable holder.
B. Insert the coupler for connecting optional part into the connector, and fix it to the bracket.
C. Insert and fix the engine stop switch coupler to the bracket.
D. Insert and fix the rectifie r/regulator coupler to the
bracket.
E. Pass the AC magneto lead to the front of the ve- hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
F. Make sure that there is no slack so that the starter motor lead cannot touch the end of the bolt.
G. Place the rear grommet of the starter motor lead matching the rear end of the side cover.
H. Insert the radiator fan motor fuse into the protru- sion of the holder plate.
I. Place the diode on top of the rear fender on the inner side of the rear frame.
J. Bring the neutral switch lead into line with the crankcase cover with no sag allowed.
K. Route the AC magneto lead inside the starter clutch cover.
L. Pass the neutral switch l ead to the inside of the
front engine bracket (the side of the vehicle).
M. Insert the plastic locking tie into the bracket hole and clamp the clutch cable. Clamp it so that the
lock of the plastic locking tie faces downward,
and then cut off the end of the plastic locking tie. N. Pass the clutch cable
with no downward sag al-
lowed.
O. Place the grommet of the clutch cable so that it contacts the radiator hose. Route the clutch cable
outside the neutral switch lead, AC magneto lead
and starter motor lead.
P. Route each lead so that the leads are not pinched
between the radiator hose and the frame.
Q. 40 mm (1.57 in)
R. Clamp the clutch cable, AC magneto lead, neu- tral switch lead and starter motor lead by the plas-
tic locking tie. Make sure that they are clamped at
the positioning tapes in the clutch cable and the
starter motor lead. Make the lock on the plastic
locking tie face the front of the vehicle, and cut
the end.
S. Clamp the starter motor lead to the inside of the tension arm with a plastic locking tie. Clamp it so
that the lock of the plastic locking tie faces up-
ward and outward, and do not cut off the end of
the plastic locking tie. R oute the lead so that there
is no slack at the bottom from the clamp position
onwards.
T. After connecting the neutral switch coupler, at- tach the coupler cover.
U. After connecting the crankshaft position sensor coupler, attach the coupler cover.
V. Pass the rectifier/regulator lead to the inside of the tension arm (the side of the vehicle).
W. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside of
the clutch cable (the side of the vehicle).
X. Pass the engine stop switch lead between the coupler for connecting optional part and the tank
rail, with the lead on the main harness side facing
the top of the vehicle.
Y. Insert the starter motor lead completely into the end of the side cover 5.
Z. Clamp the clutch cable at the front of the lead (the
front of the vehicle).
AA.Insert the clip of the pl astic locking tie into the
frame. Face the lock of the plastic locking tie for-
ward, and then cut off the end.

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.

CABLE ROUTING DIAGRAM
2-38
1. Cable guide
2. Speed sensor lead
3. Joint coupler
4. Ground lead
5. Throttle position sensor lead
6. Throttle position sensor coupler
7. Radiator breather hose
8. Radiator hose
9. Fuel hose
10. Coolant temperature sensor coupler
11. Radiator fan motor lead
12. Intake air pressure sensor coupler
13. Intake air temperature sensor coupler
14. Start switch coupler
15. Radiator fan motor coupler
16. Clutch switch coupler
17. Air filter case
18. Plate
19. Bracket
20. Radiator hose clamp
A. Pass the wire harness under the start switch lead
and clutch switch lead.
B. Insert and fix the joint co upler to the plate. After
fixing it, attach the cover.
C. Pass the throttle position sensor lead to the out- side of the tension arm (the outside of the vehi-
cle).
D. After connecting the throttle position sensor cou- pler, attach the cover.
E. Pass the radiator breather hose to the outside of the tension arm and the throttle position sensor
lead (the outside of the vehicle), and to the front
of the radiator hose (the side of the vehicle).
F. Attach the coupler cover to the coolant tempera- ture sensor coupler.
G. Pass the radiator fan motor lead to the inside of the tension arm (the side of the vehicle).
H. Install the ground lead terminal between the plate and the bolt.
I. Fix the ground lead terminal to the detent in the plate. For the ground lead terminal, either side
will do.
J. Detent
K. Route the radiator breather hose between the frame and the radiator fan motor lead coupler so
that the breather hose is not pinched.
L. Install the radiator hose clamp with the locking portion facing the front of the vehicle and tighten
the screw from the right side of the vehicle.
M. Install the radiator hose with the positioning mark facing the rear of the vehicle.

CABLE ROUTING DIAGRAM
2-42
1. Clutch switch lead
2. Engine stop switch lead
3. Clutch cable
4. Brake hose guide
5. Headlight lead
6. Speed sensor lead
7. Indicator light coupler
8. Meter assembly optional switch coupler
9. Meter assembly coupler
10. Speed sensor coupler
11. Start switch lead
12. Plastic band
13. Throttle cable
14. Front brake hose
A. Route the throttle cable, clutch cable, clutch switch lead, engine stop switch lead and start
switch lead between the cable guide of the meter
bracket and handle crown. The cables and leads
may be routed in any order.
B. Clamp the wire harness, clutch switch lead and start switch lead to the meter bracket. The clamp
shall be located at a pos ition where there is no
slack with the handle turned fully to the left.
C. Connect the headlight lead to the headlight.
D. Clamp the start switch lead to the handlebar by the plastic band.
E. Clamp the engine stop switch lead and clutch switch lead to the handlebar by the plastic band.
F. 40°±10°
G. Vertical direction
H. Pass the engine stop switch lead under the han- dlebar.