2016 YAMAHA WR 450F checking oil

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

SWINGARM
5-66
EAS2GC1217REMOVING THE SWINGARM
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Measure:• Swingarm side play
• Swingarm vertical movement
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a. Measure the tightening torque of the pivot shaft nut.
b. Measure the swingarm side play “a” by mov- ing the swingarm from side to side.
c. If the swingarm side play is out of specifica- tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b” by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
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EAS2GC1218REMOVING THE BEARING
1. Remove:• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1219CHECKING THE SWINGARM
1. Check:• Swingarm
Bends/cracks/damage  Replace.
2. Check: • Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check: • Oil seals
Damage  Replace.
• Bearing
• Spacers Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set.
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial) 1.0 mm (0.04 in)
T R..

CLUTCH......................................................................................................... 6-41
REMOVING THE CLUTCH ...................................................................... 6-44
CHECKING THE FRICTION PLATES...................................................... 6-44
CHECKING THE CLUTCH PLATES ........................................................ 6-44
CHECKING THE CLUTCH SPRINGS...................................................... 6-44
CHECKING THE CLUTCH HOUSING ..................................................... 6-45
CHECKING THE CLUTCH BOSS ............................................................ 6-45
CHECKING THE PRESSURE PLATE ..................................................... 6-45
CHECKING THE PUSH LEVER SHAFT .................................................. 6-45
CHECKING THE CLUTCH PUSH RODS ................................................ 6-45
CHECKING THE PRIMARY DRIVE GEAR .............................................. 6-45
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 6-46
INSTALLING THE OIL SEAL ................................................................... 6-46
INSTALLING THE RIGHT CRANKCASE COVER ................................... 6-46
INSTALLING THE CLUTCH ..................................................................... 6-46
INSTALLING THE KICKSTAR TER LEVER ............................................. 6-49
KICKSTATER ................................................................................................. 6-50
REMOVING THE KICK SHA FT ASSEMBLY ........................................... 6-51
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 6-51
CHECKING THE KICK GEAR, KICK IDLE GEAR AND RATCHET
WHEEL .................................................................................................... 6-51
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 6-51
INSTALLING THE KICK IDLE GEAR ....................................................... 6-52
SHIFT SHAFT ................................................................................................. 6-53
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-54
REMOVING THE SEGMENT ................................................................... 6-54
CHECKING THE SHIFT SHAFT .............................................................. 6-54
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-54
CHECKING THE STOPPER LEVER ....................................................... 6-54
INSTALLING THE STOPPE R LEVER ............................. ........................ 6-55
INSTALLING THE SEGMENT.................................................................. 6-55
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 6-55
INSTALLING THE SHIFT SHAFT ............................................................ 6-56
INSTALLING THE SHIFT PEDAL ............................................................ 6-56
OIL PUMP AND BALANCER GEAR ............................................................. 6-57
REMOVING THE BALANCER ................................................................. 6-59
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT DRIVE GEAR, AND BALANCER WEIGHT GEAR .................................. 6-59
CHECKING THE BALANCER .................................................................. 6-59
CHECKING THE OIL PUMP .................................................................... 6-59
ASSEMBLING THE OIL PUMP ................................................................ 6-60
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 6-61

GENERATOR AND STARTER CLUTCH....................................................... 6-63
REMOVING THE GENERATOR .............................................................. 6-65
CHECKING THE STARTER CLUTCH ..................................................... 6-65
INSTALLING THE STARTER CLUTCH ................................................... 6-66
INSTALLING THE GENERATOR............................................................. 6-67
CRANKCASE ................................................................................................. 6-69
DISASSEMBLING THE CRANKC ASE..................................................... 6-72
REMOVING THE CRANKCASE BEARING ............................................. 6-72
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL
STRAINER .............................................................................................. 6-72
CHECKING THE CRANKCASE ............................................................... 6-72
INSTALLING THE OIL SEAL ................................................................... 6-73
ASSEMBLING THE CRANKCASE........................................................... 6-73
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ............................... 6-74
REMOVING THE BALANCER SHAFT..................................................... 6-75
REMOVING THE CRANKSHAFT ASSEMBLY ........................................ 6-75
CHECKING THE CRANKSHA FT ASSEMBLY......................................... 6-75
INSTALLING THE CRANKSHA FT ASSEMBLY....................................... 6-76
TRANSMISSION ............................................................................................. 6-77
REMOVING THE TRANSMISSION ......................................................... 6-78
CHECKING THE SHIFT FORKS.............................................................. 6-78
CHECKING THE SHIFT DRUM ASSEMBLY ........................................... 6-79
CHECKING THE TRANSMISSION .......................................................... 6-79
INSTALLING THE TRANSMISSION ........................................................ 6-79

CAMSHAFT
6-16
EAS2GC1242CHECKING THE DECOMPRESSION SYS-
TEM
1. Check:• Decompression system
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a. Check that the decompressor cam “1”
moves smoothly.
b. Check that the decompressor lever pin “2” projects from the camshaft.
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EAS2GC1243INSTALLING THE CAMSHAFTS
1. Install:• Exhaust camshaft “1”
• Intake camshaft “2”
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a. Turn the crankshaft counterclockwise with a
wrench.
TIP
• Apply molybdenum disulfide oil to the cam-shafts.
• Apply the engine oil on the decompression
system.
b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the
crankcase cover. c. Fit the timing chain “3” onto both camshaft
sprockets and install the camshafts on the
cylinder head.
TIP
Make sure that the alignment mark “c” on the
exhaust camshaft sprocket and the alignment
mark “d” on the intake camshaft sprocket are
aligned with the edge of the cylinder head.
ECA
NOTICE
Do not turn the crankshaft during the cam-
shaft installation. Damage or improper
valve timing will result.
d. Install the clips, the camshaft caps and the bolts (camshaft cap).
TIP
• Before installing the clips, cover the cylinder head with a clean cloth to prevent the clips
from coming off into the cylinder head cavity.
• Apply the engine oil to the threads and con- tact surfaces.
• Tighten the bolts to the specified torque in two or three steps in the proper tightening se-
quence as shown.
ECA
NOTICE
The bolts (camshaft cap) must be tightened
evenly, or damage to the cylinder head,
camshaft caps, and camshaft will result.
1
2
Bolt (camshaft cap)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
ab
c
3
d
T R..

VALVES AND VALVE SPRINGS
6-29
EAS2GC1254CHECKING THE VALVE LIFTERS
1. Check:• Valve lifter
Damage/scratches  Replace the valve lift-
ers and cylinder head.
EAS2GC1255INSTALLING THE VALVES
1. Clean: • Valve stem end
2. Lubricate: • Valve stem “1”
• Valve stem seal “2” 3. Install:
• Spring seat “1”
• Valve stem seal “2”
•Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(to the cylinder head)
TIP
• Make sure each valve is installed in its original place.
• Install the valve springs with the larger pitch
“a” facing up.
4. Install: • Valve cotter “1”
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor adapter
“3”.
Recommended lubricant Molybdenum disulfide oil
b. Smaller pitch
Valve spring compressor90890-04019
Valve spring compressor YM-04019
Valve spring compressor attach-
ment 90890-04108
Valve spring compressor adapter
22 mm YM-04108
New

CYLINDER AND PISTON
6-32
EAS2GC1257REMOVING THE PISTON
1. Remove:• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clip, cover the crankcase opening with a cloth to prevent the
piston pin clip from falling into the crankcase.
• Before removing the piston pin, deburr the piston pin clip’s groove and the piston pin’s
bore area. If the piston pin groove is deburred
and the piston pin is still difficult to remove,
use the piston pin puller set “4”.
2. Remove: • Top ring
• 2nd ring
• Oil ring
TIP
When removing a piston ring, open the end gap
with your fingers and lift the opposite end gap
of the piston ring over the piston crown.
EAS2GC1258CHECKING THE CYLINDER AND PISTON
1. Check:• Piston wall (Sidewall)
• Cylinder wall
Vertical scratches  Replace the cylinder,
and replace the piston and piston rings as a
set.
2. Measure: • Piston-to-cylinder clearance
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a. Measure the cylinder bore with the cylinder
bore gauge.
TIP
Measure cylinder bore by taking side-to-side
and front-to-back measurements of the cylin-
der.
Piston pin puller set
90890-01304
Piston pin puller YU-01304
1
Bore 97.000–97.010 mm (3.8189–
3.8193 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Cylinder bore = maximum of D
1, D2, D3, D4,
D
5, D6
Taper limit (front-to-back) = maximum differ-
ence between D
1, D3, D5Taper limit (side-to-side) = maximum differ-
ence between D
2, D4, D6
Out of round limit (top) = difference between
D
1, D2Out of round limit (middle) = difference be-
tween D
3, D4Out of round limit (bottom) = difference be-
tween D
5, D6

CYLINDER AND PISTON
6-34
3. Measure:• Piston ring end gapOut of specification  Replace the piston
ring.
TIP
The oil ring expander’s end gap cannot be
measured. If the oil ring ra il’s gap is excessive,
replace all three oil rings.
EAS2GC1260CHECKING THE PISTON PIN
1. Check:
• Piston pinBlue discoloration/grooves  Replace the
piston pin and then check the lubrication
system.
2. Measure: • Piston pin outside diameter “a”
Out of specification  Replace the piston
pin. 3. Measure:
• Piston pin bore inside diameter “b”Out of specification  Replace the piston.
EAS2GC1261INSTALLING THE PISTON AND CYLINDER
1. Install:
• Oil ring expander “1”
• Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
Piston ring
Top ring
End gap (installed)0.20–0.30 mm (0.0079–0.0118 in)
Limit 0.55 mm (0.0217 in)
2nd ring End gap (installed)0.35–0.50 mm (0.0138–0.0197 in)
Limit 0.85 mm (0.0335 in)
Oil ring End gap (installed)0.20–0.50 mm (0.0079–0.0197 in)
Piston pin outside diameter 17.991–18.000 mm (0.7083–
0.7087 in)
Limit 17.971 mm (0.7075 in)
Piston pin bore inside diameter 18.004–18.015 mm (0.7088–
0.7093 in)
Limit 18.045 mm (0.7104 in)
b