2016 YAMAHA WR 450F Owners Manual

CRANKCASE
6-70
10 Crankshaft1
11 Oil nozzle 1
For assembly, reverse the disassemble pro-
cedure.
Separating the crankcase
Order Part name Q’tyRemarks
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
3
1
5
2 6410
5
5
4
4 4 46
9 7
8
11
9
LT
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.
LT

CRANKCASE
6-71
Removing the bearing and oil seal
OrderPart name Q’tyRemarks
Transmission Refer to “TRANSMISSION” on page 6-77.
Shift cam and shift fork Refer to “TRANSMISSION” on page 6-77.
1 Circlip 1
2Oil seals 3
3 Bearing 11
For installation, reverse the removal proce-
dure.
LT
LT
LT
LT
LT
12 2
3
3
33
3
3
3
3
3 3
New
NewLT

CRANKCASE
6-72
EAS2GC1311DISASSEMBLING THE CRANKCASE
1. Separate:• Right crankcase
• Left crankcase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the crankcase bolts.
TIP
Loosen each bolt 1/4 of a turn at a time and af-
ter all the bolts are loosened, remove them.
b. Remove the right crankcase “1”.
TIP
• Place the crankcase with its left side down-ward and split it by inserting a screwdriver tip
into the splitting slit “a” in the crankcase.
• Lift the right crankcase horizontally while light-
ly patting the crankcase splitting slit and the
engine mounting boss using a soft hammer,
and leave the crankshaft and the transmission
with the left crankcase.
ECA33DD041
NOTICE
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If the cases do not
separate, check for a remaining case bolt or
fitting. Do not force. c. Remove the dowel pins and O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1312REMOVING THE CRANKCASE BEARING
1. Remove:
• Bearing “1”
TIP
• Remove the bearing from the crankcase by pressing its inner race.
• Do not use the removed bearing.
EAS2GC1313CHECKING THE TIMING CHAIN, TIMING
CHAIN GUIDE, OIL STRAINER
1. Check:• Timing chainStiffness  Replace the camshaft sprocket,
timing chain and crankshaft sprocket as a
set.
2. Check: • Timing chain guide
Damage/wear  Replace
EAS2GC1314CHECKING THE CRANKCASE
1. Wash:
• Crankcase
TIP
• Wash the crankcase in a mild solvent.
• Remove any remaining gasket from the
crankcase mating surface.
2. Check: • CrankcaseCrack/damage  Replace.
1
a

CRANKCASE
6-73
• Oil delivery passagesObstruction  Blow out with compressed
air.
EAS2GC1315INSTALLING THE OIL SEAL
1. Install:
• Oil seal “1” (to left crankcase)
EAS2GC1316ASSEMBLING THE CRANKCASE
1. Install:• Bearing cover plate
TIP
• Install the bearing by pressing its outer race parallel.
• To prevent the bearing cover plate screw (crankshaft) “1” from becoming loose, crimp
the screw head periphery “a” into the concave
“b” using a punch etc. In so doing, take care
not to damage the screwdriver receiving hole
in the screw.
2. Apply: • Sealant(to the crankcase mating surface) 3. Install:
• Dowel pins “1”
• Crankcase “2”(to the left crankcase)
TIP
• Apply the lithium-soap-based grease on the
O-ring.
• Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer.
• When installing the crankcase, the connecting rod should be positioned at top dead center
(TDC).
• Tighten the bolts in a crisscross pattern in two
(2) stages, with 1/4 turn each.
Installed depth “a”
0.0–0.5 mm (0.00–0.02 in)
Bearing cover plate 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Bearing cover plate (crankshaft) 18 Nm (1.8 m·kgf, 13 ft·lbf)
New
1
a
T R..
a
b
1
1
Yamaha Bond No.121590890-85505
(Three Bond No.1215®)
Crankcase bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
3. 45 mm (1.77 in)
4. 60 mm (2.36 in)
5. 75 mm (2.95 in)
T R..
4 3
5
3
3
3
4 5
4
3
1
12

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
6-74
EAS2GC1317
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
Removing the crankshaft assembly and balancer shaft
Order Part name Q’tyRemarks
Crankcase Separate.
Refer to “CRANKCASE” on page 6-69.
Transmission Refer to “TRANSMISSION” on page 6-77.
1 Balancer shaft 1
2 Crankshaft assembly 1
For installation, reverse the removal proce-
dure.
1
2

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
6-75
EAS2GC1318REMOVING THE BALANCER SHAFT
1. Remove:• Balancer shaft “1”
TIP
Remove the balancer shaft with its flat side “a”
facing the crankshaft.
EAS2GC1319REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:• Crankshaft assembly “1”
TIP
Remove the crankshaft assembly by using the
crankcase separating tool “2”.
EAS2GC1320CHECKING THE CRANKSHAFT ASSEMBLY
1. Measure:• Crankshaft runoutOut of specification  Replace the crank-
shaft, bearing or both.
TIP
Turn the crankshaft slowly.
2. Measure: • Big end side clearance “a”Out of specification  Replace the big end
bearing, crankshaft pin, or connecting rod.
3. Measure: • Crank assembly width “a”Out of specification  Replace the crank-
shaft.
Crankcase separating tool
90890-04152
YU-A9642
1
a
2
1
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.150–0.450 mm (0.0059–0.0177
in)
Crank assembly width 61.93–62.00 mm (2.438–2.441 in)

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
6-76
4. Check:• Crankshaft sprocket “1”
Damage  Replace the crankshaft.
5. Check: • Crankshaft journal oil passageObstruction  Blow out with compressed
air.
EAS2GC1321INSTALLING THE CRANKSHAFT ASSEM-
BLY
1. Install: • Crankshaft assembly
TIP
Install the crankshaft assembly with the crank-
shaft installer pot “1”, crankshaft installer bolt
“2”, adapter (M12) “3” and spacer “4”.
ECA
NOTICE
• To avoid scratching the crankshaft and to ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease.
• In order to prevent the crankshaft seizure,
apply molybdenum disulfide grease.
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft as-
sembly bottoms against the bearing.
Crankshaft installer pot 90890-01274
Installing pot YU-90058
Crankshaft installer bolt 90890-01275
Bolt YU-90060
Adapter (M12) 90890-01278
Adapter #3 YU-90063
Spacer (crankshaft installer) 90890-04081
Pot spacer YM-91044
1

TRANSMISSION
6-77
EAS2GC1322
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
OrderPart name Q’tyRemarks
Engine Refer to “ENGINE REMOVAL” on page 6-1.
Crankcase Separate.
Refer to “CRANKCASE” on page 6-69.
1 Main axle 1
2 Drive axle 1
3 Long shift fork guide bar 1
4 Short shift fork guide bar 1
5Spring 4
6 Shift cam 1
7 Shift fork 3 (R) 1
8 Shift fork 2 (C) 1
9 Shift fork 1 (L) 1
10 Collar 1
For installation, reverse the removal proce-
dure.
2
10
1 5 3
4
5
7
8
69
M
M
M
M
M
EE
E
E
LS
New