2016 YAMAHA WR 450F oil

CHASSIS SPECIFICATIONS
2-8
Rear brakeType Hydraulic single disc brake
Operation Right foot operation
Brake pedal position 5.0 mm (0.20 in)
Rear disc brake
Disc outside diameter  thickness 245.0  4.0 mm (9.65  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm (1.00 in)
Specified brake fluid DOT 4
Steering Steering bearing type Taper roller bearing
Center to lock angle (left) 43.0 °
Center to lock angle (right) 43.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/Hydraulic damper
Front fork travel 310.0 mm (12.20 in)
Fork spring free length 470.0 mm (18.50 in)
Limit 465.0 mm (18.31 in)
Fork spring installed length 470.0 mm (18.50 in)
Spring rate K1 4.50 N/mm (0.46 kgf/mm, 25.71 lbf/in)
Spring stroke K1 0.0–310.0 mm (0.00–12.20 in)
Inner tube outer diameter 48 mm (1.9 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available Yes
Recommended oil Yamaha Suspension Oil S1
Quantity 545.0 cm
3 (18.43 US oz, 19.18 Imp.oz)
Rebound damping adjusting positions
Minimum 20 clicks out*
Standard 11 clicks out*
Maximum Fully turned in * With the adjuster fully turned in
Compression damping adjusting positions Minimum 20 clicks out*
Standard 13 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in

CHASSIS SPECIFICATIONS
2-9
Rear suspensionType Swingarm (link suspension)
Spring/shock absorber type Coil spring/Gas-hydraulic damper
Rear shock absorber assembly travel 126.0 mm (4.96 in)
Spring free length 275.0 mm (10.83 in)
Spring installed length 263.0 mm (10.35 in)
Spring rate K1 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in)
Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)
Optional spring available Yes
Enclosed gas/air pressure (STD) 980 kPa (9.8 kgf/cm
2, 139.4 psi)
Spring preload adjusting positions
Minimum Position in which the spring is turned in 1.5 mm
(0.06 in) from its free length.
Standard Position in which the spring is turned in 12 mm
(0.47 in) from its free length.
Maximum Position in which the spring is turned in 18 mm
(0.71 in) from its free length.
Rebound damping adjusting positions Minimum 30 clicks out*
Standard 14 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in
Compression damping setting
(for fast compression damping)Minimum 2 turns out*
Standard 1-3/4 turns out*
Maximum Fully turned in
* With the adjuster fully turned in
Compression damping setting
(for slow compression damping)Minimum 20 clicks out*
Standard 10 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in
Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in)
Drive chainSize/manufacturer DID520VM2/DAIDO
Number of links 114
Drive chain slack (on a suitable stand) 50.0–60.0 mm (1.97–2.36 in)
15-link length limit 239.3 mm (9.42 in)

ELECTRICAL SPECIFICATIONS
2-10
EAS2GC1064
ELECTRICAL SPECIFICATIONS
VoltageSystem voltage 12 V
Ignition systemIgnition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min
Engine control unitModel/manufacturer 2GC0/YAMAHA (USA) (CAN) 2GC1/YAMAHA (EUR) (AUS) (NZL) (ZAF)
Ignition coilMinimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k 
Spark plug cap
Resistance 7.50–12.50 k 
Lean angle sensor output voltage
Operating angle 45 °
Output voltage up to operating angle 3.7–4.4 V
Output voltage over operating angle 0.4–1.4 V
AC magneto
Standard output 14.0 V, 160 W at 5000 r/min
Stator coil resistance 0.528–0.792  (W–W)
Rectifier/regulator
Regulator type Three-phase
No load regulated voltage 14.1–14.9 V
Rectifier capacity (DC) 35.0 A
BatteryModel YTZ7S (F)
Voltage, capacity 12 V, 6.0 Ah (10HR)
Specific gravity 1.31
Manufacturer GS YUASA
Ten hour rate charging current 0.60 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage  quantity
Headlight HS1, 35.0 W/35.0 W  1 (Hi)
Tail/brake light LED
Meter lighting EL (Electroluminescent)
Indicator light
Fuel level warning light 12 V, 1.7 W  1
Engine trouble warning light 12 V, 1.7 W  1
Electric starting system
System type Constant mesh

ELECTRICAL SPECIFICATIONS
2-11
Starter motorPower output 0.48 kW
Armature coil resistance 0.0117–0.0143 
Brush overall length 7.0 mm (0.28 in)
Limit 3.50 mm (0.14 in)
Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz)
Commutator diameter 17.6 mm (0.69 in)
Limit 16.6 mm (0.65 in)
Mica undercut (depth) 1.50 mm (0.06 in)
Starter relay Amperage 180.0 A
Coil resistance 4.18–4.62 
Starting circuit cut-off relay
Coil resistance 75.7–92.5 
Headlight relay
Coil resistance 75.7–92.5 
Fuses
Main fuse 15.0 A
Radiator fan motor fuse 5.0 A
Spare fuse 15.0 A

TIGHTENING TORQUES
2-13
EAS2GC1066ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEM Thread
size Q’ty TIGHTENING TORQUES Remarks
Camshaft cap bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt (exhaust
pipe) M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head bolt M10 4See TIP.*1
Cylinder head bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage plug (cylinder head) M8 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf) Use a
lock
washer.
Balancer nut M10 1 45 Nm (4.5 m·kgf, 33 ft·lbf) Use a
lock
washer.
Timing chain guide stopper plate
(exhaust side) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator fan bolt M6 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Water pump housing cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screw M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage cover bolt (left crank-
case cover) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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TIGHTENING TORQUES
2-14
Throttle body joint clamp boltM5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter joint clamp bolt M4 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air filter case bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter bolt M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air filter guide holder screw M5 8 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Air filter case cap screw M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Starter knob/Idle screw M12 1 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf)
Throttle cable nut (pull) M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle cable nut (return) M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Clutch cable adjuster and locknut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Clutch cable locknut (engine side) M8 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Exhaust pipe nut M6 3See TIP.*2
Exhaust pipe protector screw M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe bracket bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Frame and silencer bolt (front) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Frame and silencer bolt (rear) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe clamp bolt M8 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Spark arrester bolt M5 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Muffler cap bolt M5 6 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil nozzle bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt M10 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Crankcase bolt M6 12 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Clutch cable holder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft end accessing screw M36 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing mark accessing screw M14 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Drive chain sprocket cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankcase bearing cover plate
screw M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase bearing cover plate
screw (crankshaft) M8 4 18 Nm (1.8 m·kgf, 13 ft·lbf) Crimp.
Clutch cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Left crankcase cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Right crankcase cover bolt M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil level check window bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Kick shaft ratchet wheel guide bolt M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Kickstarter lever bolt M8 1 33 Nm (3.3 m·kgf, 24 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES Remarks
LT
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TIGHTENING TORQUES
2-15
TIP
*1:Cylinder head bolt
First, tighten the cylinder head bolts to 30 Nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening sequence
and remove them. Retighten the cylinder head bolts to 20 Nm (2.0 m·kgf, 14 ft·lbf) in the proper tight-
ening sequence, and then tighten the cylinder head bolts further to reach the specified angle 150° in
the proper tightening sequence.Kickstarter lever boss screw
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Primary drive gear nut M20 1 100 Nm (10 m·kgf, 72 ft·lbf)
Clutch spring bolt M6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch boss nut M20 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
Drive sprocket nut M20 1 75 Nm (7.5 m·kgf, 54 ft·lbf) Use a
lock
washer.
Drive axle oil seal stopper bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Segment M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Shift guide bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stopper lever bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift pedal bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rotor nut M12 1 65 Nm (6.5 m·kgf, 47 ft·lbf)
Stator screw M5 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankshaft position sensor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
AC magneto lead holder bolt M5 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Damper assembly cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Starter clutch bolt M6 6 16 Nm (1.6 m·kgf, 12 ft·lbf)
Starter motor bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Starter motor cover bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Coolant temperature sensor M10 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Neutral switch bolt M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Intake air temperature sensor screw M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ECU bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Ignition coil bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle position sensor screw M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Intake air pressure sensor screw M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES Remarks
E
E
LT
LT
LT
LT
LT
LT
LT
LT

LUBRICATION POINTS AND LUBRICANT TYPES
2-21
EAS2GC1068
LUBRICATION POINTS AND LUBRICANT TYPES
EAS2GC1069ENGINE
Lubrication point Lubricant types
Oil seal lips
Bearing
O-ring
Camshaft cap bolt threads and contacting surface
Cylinder head bolt threads, seats, washers
Valve stems
Valve stem ends
Valve lifter outer surface
Camshaft lobe and journal
Valve lifter top surface
Crankshaft journal
Crankshaft big end thrust surfaces
Piston outer surface
Piston pin outer surface
Decompression system moving parts
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil passage gasket
Oil pump shaft
Kick gear and ratchet wheel
Kick shaft
Kick idle gear inner surface
Ratchet wheel and ratchet wheel guide contacting portion
Primary drive gear nut threads and contacting surface
Primary driven gear inner surface and end surface
Clutch push rod washer
Clutch push rod 1 outer surface
Clutch push rod 1 thrust surface
Clutch push rod 2 outer surface
Push lever shaft outer surface
Transmission gear inner surface (wheel and pinion) and collar
Transmission gears (shift fork groove)
Shift cam grooves
Shift fork and shift fork guide outer surface
Shift shaft and collar
Shift lever assembly moving parts
Damper assembly shaft, thrust surfaces, washers
LS
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LS
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LS
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