2016 YAMAHA WR 450F Owners Manual

TRANSMISSION
6-78
EAS2GC1323REMOVING THE TRANSMISSION
1. Remove:• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Shift cam “3”
• Shift fork 3 “4”
• Shift fork 2 “5”
• Shift fork 1 “6”
• Main axle “7”
• Drive axle “8”
• Collar “9”
TIP
• Remove assembly with the collar “9” installed to the crankcase.
• Make a note of the position of each part. Pay particular attention to the location and direc-
tion of shift forks.
• Remove the main axle and the drive axle all together by tapping the drive axle lightly with
a soft hammer.
EAS2GC1324CHECKING THE SHIFT FORKS
1. Check:• Shift fork cam follower “1”
• Shift fork pawl “2”Bends/damage/scoring/wear  Replace the
shift fork.
2. Check: • Shift fork guide barRoll the shift fork guide bar on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement  Replace the shift forks
and shift fork guide bar as a set.
1
4 6 2
53
8
7
9

TRANSMISSION
6-79
EAS2GC1325CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:• Shift drum grooveDamage/scratches/wear  Replace the
shift drum assembly.
• Shift drum segment “1” Damage/wear  Replace the shift drum as-
sembly.
EAS2GC1326CHECKING THE TRANSMISSION
1. Measure: • Main axle runout(with a centering device and dial gauge “1”)
Out of specification  Replace the main ax-
le.
2. Measure: • Drive axle runout(with a centering device and dial gauge “1”)
Out of specification  Replace the drive ax-
le. 3. Check:
• Transmission gears
Blue discoloration/pitting/wear  Replace
the defective gear (s).
• Transmission gear dogs
Cracks/damage/rounded edges  Replace
the defective gear (s).
4. Check:
• Transmission gear movementRough movement  Replace the defective
gear (s).
EAS2GC1327INSTALLING THE TRANSMISSION
1. Install:
• 5th pinion gear (25T) “1”
• 3rd pinion gear (16T) “2”
• Collar “3”
• 4th pinion gear (20T) “4”
• 2nd pinion gear (15T) “5”(to the main axle “6”)
TIP
Before installation, apply molybdenum disulfide
oil to the inner and end surface of the idler gear
and to the inner surface of the sliding gear, then
install.
Main axle runout limit
0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
3 4
2
1
6
5
M

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

7
COOLING SYSTEM
RADIATOR....................................................................................................... 7-1
HANDLING NOTE ...................................................................................... 7-3
CHECKING THE RADIATOR ..................................................................... 7-3
WATER PUMP .................................................................................................. 7-4
REMOVING THE OIL SEAL ....................................................................... 7-5
CHECKING THE WATER PUMP ............................................................... 7-5
CHECKING THE BEARING ....................................................................... 7-5
INSTALLING THE OIL SEAL ..................................................................... 7-5
ASSEMBLING THE WATER PUMP........................................................... 7-5

RADIATOR
7-1
EAS2GC1328
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, serv ice engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS2GC1329
RADIATOR
Removing the radiator
OrderPart name Q’tyRemarks
Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
Air filter case Refer to “THROTTLE BODY” on page 8-7.
1 Radiator guard 2
2 Radiator hose clamp 8 Loosen.
3 Radiator fan 1
12
13
New
New
New
LS
LS
3
4 58 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
6
7
8 9
10
11 2
2
2
2
2
2
2
1
1

RADIATOR
7-2
4 Right radiator1
5 Radiator hose 2 1
6 Radiator hose 3 1
7 Radiator hose 4 1
8 Radiator pipe 2 1
9 Radiator breather hose 1
10 Left radiator 1
11 Radiator hose 1 1
12 Radiator pipe 1 1
13 Coolant temperature sensor 1
For installation, reverse the removal proce-
dure.
Removing the radiator
Order Part name Q’tyRemarks
12
13
New
New
New
LS
LS
3
4 58 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
6
7
8 9
10
11 2
2
2
2
2
2
2
1
1

RADIATOR
7-3
EAS2GC1330HANDLING NOTEEWA
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
EAS2GC1331CHECKING THE RADIATOR
1. Check:• Radiator fins “1”
Obstructions  Clean.
Apply compressed air to the rear of the radi-
ator.
Damage  Repair or replace.
TIP
Correct any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• Radiator hoses
• Radiator pipes
Crack/damage  Replace.