2016 YAMAHA WR 450F transmission oil

TRANSMISSION
6-80
2. Install:• Collar “1”
• 2nd wheel gear (26T) “2”
• 4th wheel gear (21T) “3”
• 3rd wheel gear (21T) “4”
• 5th wheel gear (21T) “5”
• Collar “6”
• 1st wheel gear (29T) “7”
• O-rings “8” (to the drive axle “9”)
TIP
• Before installation, apply molybdenum disul-fide oil to the inner and end surface of the idler
gear and the collar and to the inner surface of
the sliding gear, then install.
• Apply the lithium-soap-based grease on the
O-ring.
3. Install: • Washer “1”
• Circlip “2”
TIP
• Be sure the circlip sharp-edged corner “a” is positioned opposite side to the washer and
gear “b”.
• Install the circlip with its ends “c” settled even-
ly on the spline crests. 4. Install:
• Collar “1”
TIP
• Apply the lithium-soap-based grease on the oil seal lip.
• When installing the collar into the crankcase, pay careful attention to the crankcase oil seal
lip.
5. Install: • Main axle “1”
• Drive axle “2”
TIP
• Install to the left crankcase simultaneously.
• Apply engine oil to the main axle and the drive
axle bearing.
New
2 9
8
3
4
5
6
7
New
MM
LS
M
1
New
2 1
2
ab
cc
1
2
EE

TRANSMISSION
6-81
6. Install:• Shift fork 1 (L) “1”
• Shift fork 2 (C) “2”
• Shift fork 3 (R) “3”
• Shift cam “4”(to the main axle and the drive axle)
TIP
• Apply engine oil to the shift fork grooves.
• Apply engine oil to the shift cam groove and
the bearing contact surface.
• Mesh the shift fork 1 (L) with the 4th wheel gear “5” and shift fork 3 (R) with the 5th wheel
gear “7” on the drive axle.
• Mesh the shift fork 2 (C) with the 3rd pinion
gear “6” on the main axle. 7. Install:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Spring “3”
TIP
• Screw the spring into the shift fork guide bar lightly beforehand.
• Apply the engine oil on the shift fork guide
bars.
8. Check: • Operation of shift cam and shift fork
• Transmission operationUnsmooth operation  Repair.
3
12
EE
E
2
1 3
E

TROUBLESHOOTING
10-2
Electrical system
1. Battery• Discharged battery
• Faulty battery
2. Spark plug • Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coil
• Cracked or broken ignition coil
4. Ignition system • Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
EAS2GC1410POOR MEDIUM-AND-HIGH-SPEED PER-
FORMANCE
Refer to “STARTING FAILURES” on page 10-
1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump • Faulty fuel pump
2. Throttle body
• Defective throttle body
3. ECU • Faulty ECU
EAS2GC1411SHIFTING IS DIFFICULT
Refer to “CLUTCH” on page 6-41.
EAS2GC1412SHIFT PEDAL DOES NOT MOVE
Engine
1. Shift shaft
• Bent shift shaft
2. Shift drum and shift forks • Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
3. Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EAS2GC1413
JUMPS OUT OF GEAR
Engine
1. Shift shaft• Incorrect shift pedal position
• Improperly returned stopper lever
2. Shift forks
• Worn shift fork
3. Shift drum • Incorrect axial play
• Worn shift drum groove
4. Transmission • Worn gear dog
EAS2GC1414CLUTCH SLIPS
Engine
1. Clutch• Improperly assembled clutch
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
EAS2GC1415CLUTCH DRAGS
Engine
1. Clutch• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Damaged clutch boss
• Burnt primary driven gear bushing
2. Engine oil • Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS2GC1416OVERHEATING
Engine
1. Cylinder head and piston• Heavy carbon buildup
• Clogged coolant passages
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality