2016 YAMAHA WR 450F length

CHASSIS
4-6
EAS2GC1148SUSPENSION SETTING (FRONT FORK)
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absor ber sunken length to the standard figure 90–100 mm
(3.5–3.9 in).
Symptom Section
CheckAdjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff over entire
range Compression
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil amount Decrease oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with soft spring.
Unsmooth
movement over
entire range Outer tube
Inner tube
Check for any bends, dents,
other noticeable scars, etc. If
any, replace affected parts.
Slide metal Replace with a new one for ex- tended use.
Piston metal Replace with a new one for ex- tended use.
Lower bracket
tightening
torque Retighten to specified torque.
Poor initial
movement Rebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil seals Apply grease in oil seal wall.
Soft over entire
range, bottom-
ing out Compression
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Oil amount Increase oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with stiff spring.
Stiff toward
stroke end Oil amountDecrease oil amount by about
5 cm
3 (0.2 US oz, 0.2 Imp.oz).
Soft toward
stroke end, bot-
toming out Oil amountIncrease oil amount by about 5
cm
3 (0.2 US oz, 0.2 Imp.oz).
Stiff initial
movement Compression
damping forceTurn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.

CHASSIS
4-7
EAS2GC1149SUSPENSION SETTING (REAR SHOCK ABSORBER)
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2- click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.Low front, tend-
ing to lower
front posture
Compression
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Rebound
damping force Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Balance with
rear end Set sunken length for 95–100
mm (3.7–3.9 in) when one
passenger is astride seat (low-
er rear posture).
Oil amount Increase oil amount by about 5 cm
3 (0.2 US oz, 0.2 Imp.oz).
“Obtrusive”
front, tending to
upper front pos-
ture Compression
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Balance with
rear end Set sunken length for 90–95
mm (3.5–3.7 in) when one
passenger is astride seat (up-
per rear posture).
Spring Replace with soft spring.
Oil amount Decrease oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Symptom Section
Check Adjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff, tending to
sink Rebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Spring set
length Set sunken length for 90–100
mm (3.5–3.9 in) when one
passenger is astride seat.
Spongy and un-
stable Rebound
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Low compres-
sion damping Turn adjuster clockwise (about
1 click) to increase damping.
Spring Replace with stiff spring.
Symptom
Section
Check Adjust
Jump Large
gap Medi-
um
gap Small
gap

CHASSIS
4-8
Heavy and
draggingRebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Spring Replace with soft spring.
Poor road grip-
ping Rebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Low compres-
sion damping Turn adjuster clockwise (about
1 click) to increase damping.
High compres-
sion damping Turn adjuster clockwise (about
1/6 turn) to increase damping.
Spring set
length Set sunken length for 90–100
mm (3.5–3.9 in) when one
passenger is astride seat.
Spring Replace with soft spring.
Bottoming out High compres-
sion damping
Turn adjuster clockwise (about
1/6 turn) to increase damping.
Spring set
length Set sunken length for 90–100
mm (3.5–3.9 in) when one
passenger is astride seat.
Spring Replace with stiff spring.
Bouncing Rebound
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Spring Replace with soft spring.
Stiff travel High compres-
sion damping
Turn adjuster counterclock-
wise (about 1/6 turn) to de-
crease damping.
Spring set
length Set sunken length for 90–100
mm (3.5–3.9 in) when one
passenger is astride seat.
Spring Replace with soft spring.
Symptom
Section
CheckAdjust
Jump Large
gap Medi-
um
gap Small
gap

FRONT FORK
5-43
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5. Remove:• Base valve “1”
(from the damper assembly)
TIP
Hold the damper assembly with the cap bolt
ring wrench “2” and use the cap bolt wrench “3”
to remove the base valve.
EAS2GC1200CHECKING THE FRONT FORK LEGS
1. Check:• Inner tube surface “a”Scratches  Repair or replace.
Use #1000 grit wet sandpaper.
Damaged oil lock piece  Replace.
• Inner tube bends Out of specification  Replace.
Use the dial gauge “1”.
TIP
The bending value is shown by one half of the
dial gauge reading.
EWA
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Check:
• Outer tubeScratches/wear/damage  Replace.
3. Measure:
• Fork spring free length “a”Out of specification  Replace.
4. Check: • Damper assembly “1”Bend/damage  Replace.
• O-ring “2” Wear/damage  Replace.
ECA
NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
Cap bolt wrench
90890-01500
Cap bolt wrench YM-01500
Cap bolt ring wrench 90890-01501
Cap bolt ring wrench YM-01501
Inner tube bending limit 0.2 mm (0.01 in)
1
2 3
Fork spring free length
470.0 mm (18.50 in)
Limit 465.0 mm (18.31 in)

CHAIN DRIVE
5-69
EAS23420REMOVING THE DRIVE CHAIN
1. Stand the vehicle on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
2. Remove:•Drive chain
TIP
Cut the drive chain with the drive chain cut &
rivet tool. (Use goods on the market)
EAS23441CHECKING THE DRIVE CHAIN
1. Measure:• 15-link section of the drive chain
Out of specification  Replace the drive
chain.
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a. Measure the length “a” between the inner sides of the pins and the length “b” between
the outer sides of the pins on a 15-link sec-
tion of the drive chain as shown in the illus-
tration.
b. Calculate the length “c” of the 15-link section of the drive chain using the following formu-
la.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
TIP
• When measuring a 15-link section of the drive chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a differ-
ent location each time.
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2. Check: •Drive chain
Stiffness  Clean, lubricate, or replace.
3. Clean: •Drive chain
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a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove any remaining dirt.
c. Remove the drive chain from the kerosene and completely dry it.
ECA
NOTICE
• This vehicle has a drive chain with small
rubber O-rings “1” between the drive
chain side plates. Never use high-pressure
water or air, steam, gasoline, certain sol-
vents (e.g., benzine), or a coarse brush to
clean the drive chain. High-pressure meth-
ods could force dirt or water into the drive
chain’s internals, and solvents will deteri-
orate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosene to clean the drive chain.
• Do not soak the drive chain in kerosene for more than ten minutes, otherwise the O-
rings can be damaged.
15-link length limit
239.3 mm (9.42 in)

VALVES AND VALVE SPRINGS
6-28
g. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat contact width “c” again. If the valve seat contact width is out of
specification, reface and lap the valve seat.
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EAS2GC1253CHECKING THE VALVE SPRINGS
1. Measure:
• Valve spring free length “a”Out of specification  Replace the valve
spring. 2. Measure:
• Compressed valve spring force “a”
Out of specification  Replace the valve
spring.
3. Measure: • Valve spring tilt “a”Out of specification  Replace the valve
spring.
Free length (intake)
40.76 mm (1.60 in)
Limit 38.72 mm (1.52 in)
Free length (exhaust) 36.94 mm (1.45 in)
Limit 35.09 mm (1.38 in)
b. Installed length
Installed compression spring
force (intake) 178.00–204.00 N (18.15–20.80
kgf, 40.01–45.86 lbf)
Installed compression spring
force (exhaust) 124.00–142.00 N (12.64–14.48
kgf, 27.88–31.92 lbf)
Installed length (intake) 34.78 mm (1.37 in)
Installed length (exhaust) 30.83 mm (1.21 in)
Spring tilt (intake) 2.5 °/1.8 mm (2.5 °/0.07 in)
Spring tilt (exhaust) 2.5 °/1.6 mm (2.5 °/0.06 in)

ELECTRIC STARTER
6-38
EAS2GC1263CHECKING THE STARTER MOTOR
1. Check:•CommutatorDirt  Clean with 600 grit sandpaper.
2. Measure: • Commutator diameter “a”Out of specification  Replace the starter
motor.
3. Measure: • Mica undercut “a”Out of specification  Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the com-
mutator.
TIP
The mica of the commutator must be undercut
to ensure proper operation of the commutator.
4. Measure: • Armature assembly resistances (commuta-
tor and insulation)
Out of specification  Replace the starter
motor.
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a. Measure the armature assembly resistanc-
es with the pocket tester.
b. If any resistance is out of specification, re- place the starter motor.
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5. Measure:• Brush length “a”Out of specification  Replace the brush
set.
6. Measure: • Brush spring force
Out of specification  Replace the brush
set.
Limit
16.6 mm (0.65 in)
Mica undercut (depth) 1.50 mm (0.06 in)
Pocket tester90890-03112
Analog pocket tester YU-03112-C
Armature coil Commutator resistance “1” 0.0117–0.0143 
Insulation resistance “2” Above 1 M 
Limit 3.50 mm (0.14 in)
Brush spring force 3.92–5.88 N (400–600 gf, 14.11–
21.17 oz)

CLUTCH
6-44
EAS2GC1266REMOVING THE CLUTCH
1. Remove:• Clutch boss nut “1”
• Conical washer “2”
• Clutch boss “3”
TIP
While holding the clutch boss with the clutch
holder “4”, loosen the clutch boss nut.
EAS2GC1267CHECKING THE FRICTION PLATES
1. Check:• Friction plate
Damage/wear  Replace the friction plates
as a set.
2. Measure:
• Friction plate thicknessOut of specification  Replace the friction
plates as a set.
TIP
Measure it at four points on the friction plate.
EAS2GC1268
CHECKING THE CLUTCH PLATES
1. Check: • Clutch plate
Damage  Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage(with a surface plate and thickness gauge
“1”)
Out of specification  Replace the clutch
plates as a set.
EAS2GC1269CHECKING THE CLUTCH SPRINGS
1. Check: • Clutch springDamage  Replace the clutch springs as a
set.
2. Measure: • Clutch spring free lengthOut of specification  Replace the clutch
springs as a set.
Universal clutch holder
90890-04086
Universal clutch holder YM-91042
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.85 mm (0.112 in)
3 4
12
Warpage limit
0.10 mm (0.004 in)
Clutch spring free length 50.00 mm (1.97 in)
Limit 47.50 mm (1.87 in)