2016 YAMAHA WR 450F coolant

PERIODIC MAINTENANCE
3-2
EAS2GC1077GENERAL MAINTENANCE AND LUBRICATION CHARTNO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER READ-
INGS
600 mi (1000
km) or 1 month 1800 mi
(3000
km) or 3 months 3000 mi
(5000
km) or 6 months
1Clutch • Check operation.
• Adjust or replace cable. 
2*Cooling sys-
tem • Check hoses for cracks of damage.
• Replace if necessary.

• Replace with ethylene glycol anti- freeze coolant every 1 year. Every 1 year
3*Spark arrest-
er • Clean.

4*Front brake • Check operation, fluid level, and for flu-
id leakage.
• Replace brake pads if necessary. 
• Replace brake fluid every 1 year. Every 1 year
5* Rear brake • Check operation, fluid level, and for flu-
id leakage.
• Replace brake pads if necessary. 
• Replace brake fluid every 1 year. Every 1 year
6* Brake hoses • Check for cracks or damage.

• Replace. Every 4 years
7*Wheels • Check runout, spoke tightness and for
damage.
• Tighten spokes if necessary. 
8*
Tires • Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. 
9*
Wheel bear-
ings • Check bearings for smooth operation.
• Replace if necessary.

10*Swingarm
pivot bear-
ings • Check bearing assemblies for loose-
ness.
• Moderately repack with lithium-soap- based grease. 
11Drive chain• Check chain slack/alignment and con-
dition.
• Adjust and lubricate chain with a spe- cial O-ring chain lubricant thoroughly. Every ride
12*
Steering
bearings • Check bearing assemblies for loose-
ness.
• Moderately repack with lithium-soap- based grease every 1200 mi (2000
km) or 12 months (whichever comes
first). 

PERIODIC MAINTENANCE
3-6
COOLING SYSTEMCheck coolant lev-
el and leakage
Check radiator cap
operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS
AND BOLTS
Retighten Refer to “STARTING AND
BREAK-IN” on page 1-28.
AIR FILTER
Clean and lubri-
cate Use Yamaha foam air filter oil
or other quality foam air filter
oil.
Replace
OIL FILTER
Replace
ENGINE GUARD Replace Breakage
FRAME Clean and inspect
FUEL TANK, FUEL
PUMP
Clean and inspect
FUEL HOSE Inspect
Replace Every four years
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
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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 REMOVAL
6-3
Removing the electronic parts
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
Air filter case cover
1 Rectifier/regulator 1
2ECU 1
3 Ignition coil 1
4 Neutral switch 1
5 AC magneto coupler 1 Disconnect.
6 Crankshaft position sensor coupler 1 Disconnect.
7 Coolant temperature sens or coupler1 Disconnect.
For installation, reverse the removal proce-
dure.
T.R.
T.R.
T.R.T.R.
7
3
6 5
1 4 2
LT
New
LS

CYLINDER HEAD
6-18
EAS2GC1244
CYLINDER HEAD
Removing the cylinder head
OrderPart name Q’tyRemarks
Refer to “INSTALLING THE CYLINDER
HEAD” on page 6-21.
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 6-1.
Radiator hose Disconnect.
Coolant temperature sens or coupler Disconnect.
Throttle body Refer to “THROTTLE BODY” on page 8-7.
Camshaft Refer to “CAMSHAFT” on page 6-11.
Upper engine bracket Refer to “ENGINE REMOVAL” on page 6-1.
1 Bolt (cylinder head) 2
2 Engine ground sub-lead 1
3 Bolt (cylinder head) 4
4 Cylinder head 1
8
6
7
7
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
15 Nm (1.5 m kgf, 11 ft Ibf)T.R.
*
20 Nm (2.0 mkgf, 14 ftIbf)T.
R.
30 Nm (3.0 mkgf, 22 ftIbf)
2
4 3
3
5
1
1
*