2016 YAMAHA WR 450F relay

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

HANDLEBAR................................................................................................. 5-33
REMOVING THE HANDLEBAR ............................................................... 5-35
CHECKING THE HANDLEBAR ............................................................... 5-35
INSTALLING THE HANDLEBAR ............................................................. 5-35
FRONT FORK ................................................................................................. 5-40
REMOVING THE FRONT FORK LEGS ................................................... 5-42
DISASSEMBLING THE FRONT FO RK LEGS ......................................... 5-42
CHECKING THE FRONT FORK LEGS ................................................... 5-43
ASSEMBLING THE FRONT FORK LEGS ............................................... 5-44
INSTALLING THE FRONT FORK LEGS ................................................. 5-50
STEERING HEAD ........................................................................................... 5-53
REMOVING THE LOWER BRACKET...................................................... 5-55
CHECKING THE STEERING HEAD ........................................................ 5-55
INSTALLING THE STEERING HEAD ...................................................... 5-55
REAR SHOCK ABSORBER ASSEMBLY ..................................................... 5-58
HANDLING THE REAR SHOCK ABSORBER ......................................... 5-61
DISPOSING OF A REAR SH OCK ABSORBER ...................................... 5-61
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................... 5-61
REMOVING THE BEARING..................................................................... 5-61
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................... 5-62
CHECKING THE CONNECTING ARM AND RELAY ARM ...................... 5-62
INSTALLING THE RELAY ARM............................................................... 5-62
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY .................. 5-63
SWINGARM .................................................................................................... 5-65
REMOVING THE SWINGARM................................................................. 5-66
REMOVING THE BEARING..................................................................... 5-66
CHECKING THE SWINGARM ................................................................. 5-66
INSTALLING THE SWINGARM ............................................................... 5-67
CHAIN DRIVE ................................................................................................. 5-68
REMOVING THE DRIVE CHAIN.............................................................. 5-69
CHECKING THE DRIVE CHAIN .............................................................. 5-69
CHECKING THE DRIVE SPROCKET...................................................... 5-70
CHECKING THE REAR WHEEL SPROCKET ......................................... 5-70
INSTALLING THE DRIVE CHAIN ............................................................ 5-70

REAR SHOCK ABSORBER ASSEMBLY
5-60
Disassembling the relay arm
OrderPart name Q’tyRemarks
1 Relay arm 1
2 Connecting arm 1
3Collars 3
4Oil seals 6
5Washers 8
6 Bearing 6
For assembly, reverse the disassemble pro-
cedure.
5
3
5
6
165
4
5
5
4
56
6
5
4
3
2
4
6
6
3
4
4
T.R.80 Nm (8.0 mlbf)
kgf, 58 ft
M
M
M
M
M
M M

REAR SHOCK ABSORBER ASSEMBLY
5-62
2. Remove:• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1212CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
•Spring
Damage/wear  Replace. • Spring guide
Damage/wear  Replace.
• Bearing
Damage/wear  Replace.
•Bolts Bends/damage/wear  Replace.
EAS2GC1213CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
2. Check: • Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check: • Oil sealsDamage/pitting  Replace.
EAS2GC1214INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install: • Bearing “1”
• Washer “2”
• Oil seals “3” (to relay arm “4”)
1
Recommended lubricantMolybdenum disulfide grease
Installed depth “a” 0 mm (0 in)
New
3
3
43
2 2
2 2
a
1 1 1

REAR SHOCK ABSORBER ASSEMBLY
5-63
3. Install:• Bearing “1”
• Oil seals “2” (to connecting arm “3”)
EAS2GC1215INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY
1. Lubricate:• Bearing (lower side)
•Dust seal
•Collars
• Bushing
ECA
NOTICE
Do not apply the grease to the bearing outer
race because it will wear the rear shock ab-
sorber surface on which the bearing is
press fitted.
2. Lubricate:• O-ring
3. Install: • Bearing
• Stopper ring (to rear shock absorber assembly (upper
side))
TIP
• Install the bearing parallel until the stopper ring groove appears by pressing its outer
race.
• After installing the stopper ring, push back the
bearing unit it contacts the stopper ring. 4. Install:
• Bearing “1”
• Bushing “2”
• Collar “3”
• Dust seal “4”(to rear shock absorber assembly (lower
side))
TIP
Install the dust seals with their lips facing in-
ward.
5. Lubricate:
• Connecting arm and frame bolt
• Relay arm and connecting arm bolt
• Relay arm and swingarm bolt(circumference and threaded portion)
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly lower bolt
6. Install: • Rear shock absorber assembly
TIP
• When installing the rear shock absorber as-sembly, lift up the swingarm.
• Install the rear shock absorber assembly up- per bolt, and connecting arm bolt (frame side)
from the right.
• Install the rear shock absorber assembly low- er bolts, connecting arm bolt (relay arm side),
and relay arm bolt (swingarm side) from the
left.
Installed depth “a”
0 mm (0 in)
Recommended lubricant Molybdenum disulfide grease
Recommended lubricant Lithium-soap-based grease
New
3
a
1
1 2
a
2
New
Installed depth “a” 4.25 mm (0.17 in)
Recommended lubricant Molybdenum disulfide grease

REAR SHOCK ABSORBER ASSEMBLY
5-64
7. Tighten:• Rear shock absorber assembly upper bolt
• Connecting arm bolt (frame side)
• Connecting arm bolt (relay arm side)
• Relay arm bolt (swingarm side)
• Rear shock absorber assembly lower bolt Rear shock absorber assembly
upper bolt
56 Nm (5.6 m·kgf, 41 ft·lbf)
Connecting arm bolt (frame side) 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (relay arm
side) 80 Nm (8.0 m·kgf, 58 ft·lbf)
Relay arm bolt (swingarm side) 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear shock absorber assembly
lower bolt 53 Nm (5.3 m·kgf, 38 ft·lbf)
T R..
T R..
T R..
T R..
T R..

ENGINE REMOVAL
6-1
EAS2GC1225
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, serv ice engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS2GC1226
ENGINE REMOVAL
Removing the exhaust pipe
OrderPart name Q’tyRemarks
Refer to “INSTALLING THE EXHAUST
PIPE AND MUFFLER” on page 6-9.
Side cover (right) Refer to “GENERAL CHASSIS” on page 5-1.
Rear shock absorber assembly lower bolt Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
Connecting arm bolt (relay arm side) Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
Starter motor Refer to “ELECTRIC STARTER” on page 6-
36.
1 Silencer clamp 1 Loosen.
2 Silencer 1
3 Exhaust pipe 2 clamp 1 Loosen.
105
9
26
1 6 6
3
8 4
7
(4)
(6)
30 Nm (3.0 m kgf, 22 ft Ibf)T
.R.
30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
New
New
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
20 Nm (2.0 m kgf, 14 ft Ibf)T.R.New
LT
LT
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.9 Nm (0.9 m kgf, 6.5 ft Ibf)T .R.
5 Nm (0.5 m kgf, 3.6 ft Ibf)T.R.
T
.R.*kgf
7 Nm (0.7 m , 5.1 ft lbf)
10 Nm (1.0 m kgf, 7.2 ft Ibf)
*

ENGINE REMOVAL
6-6
EAS2GC1227REMOVING THE SILENCER
1. Remove:• Rear shock absorber assembly lower bolt “1”
• Connecting arm bolt (relay arm side) “2”
• Silencer “3”
TIP
Move the rear shock absorber to the left side of
the chassis, and remove the silencer.
EAS2GC1228REMOVING THE EXHAUST PIPE 2
1. Remove: • Starter motor
Refer to “ELECTRIC STARTER” on page 6-
36.
• Exhaust pipe 2
TIP
Put the Exhaust pipe 2 into the state as shown
by moving this, and then remove it.
EAS2GC1229REMOVING THE DRIVE SPROCKET
1. Straighten the lock washer tab.
2. Remove:
• Nut (drive sprocket) “1”
• Lock washer “2”
TIP
Loosen the nut while applying the rear brake.
3. Remove:• Drive sprocket “1”
• Drive chain “2”
TIP
Remove the drive sprocket together with the
drive chain.
1 2
3