2016 YAMAHA WR 450F Owners Manual

BASIC SERVICE INFORMATION
1-11
Checking the connections
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:• Lead
• Coupler
• Connector
ECA
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the
coupler, and then disconnect the coupler.
• There are many types of coupler locks; therefore, be sure to check the type of cou-
pler lock before disconnecting the cou-
pler.
ECA
NOTICE
When disconnecting a connector, do not
pull the leads. Hold both sections of the
connector, and then disconnect the con-
nector. 2. Check:
• Lead
• Coupler
• ConnectorMoisture  Dry with compressed air.
Rust/stains  Connect and disconnect sev-
eral times.
3. Check: • All connectionsLoose connection  Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.
1

BASIC SERVICE INFORMATION
1-12
4. Connect:• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, make sure that both terminals are connected
securely.
• Make sure all connections are tight.
5. Check:• No continuity
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores. Pocket tester
90890-03112
Analog pocket tester YU-03112-C

SPECIAL TOOLS
1-13
EAS2GC1028
SPECIAL TOOLS
The following special tools are required for accurate and complete adjustment and assembly. Using
the correct special tool will help prevent damage ca used by the use of improper tools or improvised
techniques. The shape and tool number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
TIP
• For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use tool number starting with “90890-”.
Tool name/Part number How to use Illustration
Dial gauge & stand set
90890-01252
Dial gauge set
YU-03097-B This tool is used to check
parts for runout or bend.
Crankshaft installer pot
90890-01274
Installing pot
YU-90058 This tool is used to install the
crankshaft.
Crankshaft installer bolt
90890-01275
Bolt
YU-90060 This tool is used to install the
crankshaft.
Adapter (M12)
90890-01278
Adapter #3
YU-90063 This tool is used to install the
crankshaft.
Piston pin puller set
90890-01304
Piston pin puller
YU-01304 This tool is used to remove
the piston pin.

SPECIAL TOOLS
1-14
Radiator cap tester
90890-01325
Mityvac cooling system tester
kit
YU-24460-AThis tool is used to check the
radiator and the radiator cap.
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984 This tool is used to check the
radiator and the radiator cap.
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472 This tool is used to remove or
tighten the steering nut.
Cap bolt wrench
90890-01500
Cap bolt wrench
YM-01500 This tool is used to remove or
tighten the base valve.
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501 This tool is used to loosen or
tighten the damper assem-
bly.
Fork seal driver
90890-01502
Fork seal driver (48)
YM-A0948 This tool is used to install the
oil seal of the front fork.
Spoke nipple wrench (6–7)
90890-01521
Spoke nipple wrench (6–7)
YM-01521 This tool is used to tighten the
spoke.
Tool name/Part number How to use Illustration

SPECIAL TOOLS
1-15
Pocket tester
90890-03112
Analog pocket tester
YU-03112-CThis tool is used to measure
the voltage, current, and re-
sistance of electrical compo-
nents.
Timing light
90890-03141
Timing light
YU-03141 This tool is used to measure
the ignition timing.
Pressure gauge
90890-03153
Pressure gauge
YU-03153 This tool is used to measure
the fuel pressure.
Fuel pressure adapter
90890-03186
Fuel pressure adapter
YM-03186 This tool is used to mount the
pressure gauge.
Test harness S– pressure
sensor (3P)
90890-03207
Test harness S– pressure
sensor (3P)
YU-03207 This tool is used to check the
throttle position sensor input
voltage.
Test harness– lean angle
sensor (6P)
90890-03209
Test harness– lean angle
sensor (6P) This tool is used to check the
lean angle sensor output volt-
age.
FI diagnostic tool sub–lead
90890-03212
FI diagnostic tool sub–lead
YU-03212 This tool is used to connect
the Yamaha diagnostic tool
to a battery.
Test harness– speed sensor
5TJ (3P)
90890-03228
Test harness– speed sensor
5TJ (3P)
YU-03228 This tool is used to check the
speed sensor output voltage.
Yamaha diagnostic tool
90890-03231
Yamaha diagnostic tool (US)
90890-03234 This tool is used to check er-
ror codes or carry out self-di-
agnosis.
Tool name/Part number
How to useIllustration

SPECIAL TOOLS
1-16
Valve guide remover & in-
staller set (ø5.5)
90890-04016
Valve guide remover (5.5
mm)
YM-01122
Valve guide installer (5.5
mm)
YM-04015
Valve guide reamer (5.5 mm)
90890-01196This tool is used to replace
the valve guide.
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019 This tool is used to discon-
nect or connect the valve and
the valve spring.
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044 This tool is used to install the
crankshaft.
Universal clutch holder
90890-04086
Universal clutch holder
YM-91042 This tool is used to hold the
clutch when removing or in-
stalling the clutch boss secur-
ing nut.
Valve lapper
90890-04101
Valve lapping tool
YM-A8998 This tool is used to remove
the valve lifter or lap the
valve.
Tool name/Part number
How to useIllustration
YM-04019
YM-91044

SPECIAL TOOLS
1-17
Valve spring compressor at-
tachment
90890-04108
Valve spring compressor
adapter 22 mm
YM-04108This tool is used to discon-
nect or connect the valve and
the valve spring.
Rotor puller
90890-04142
Rotor puller
YM-04142 This tool is used to remove
the rotor.
Crankcase separating tool
90890-04152
Crankcase separating tool
YU-A9642 This tool is used to remove
the crankshaft.
Ignition checker
90890-06754
Oppama pet–4000 spark
checker
YM-34487 This tool is used to check the
spark performance of the ig-
nition coil.
Digital tachometer
90890-06760
Digital tachometer
YU-39951-B This tool is used to measure
the engine speed.
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®) This sealant (Bond) is used
for crankcase mating sur-
face, etc.
Tool name/Part number How to use Illustration

CONTROL FUNCTIONS
1-18
EAS2GC1029
CONTROL FUNCTIONS
EAS2GC1030INDICATOR LIGHTS AND WARNING
LIGHTS
Fuel level warning light “ ”
This warning light comes on when the fuel level
drops below approximately 1.6 L (0.42 US gal,
0.35 Imp.gal). When this occurs, refuel as soon
as possible.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the start switch is pushed, or if the warn-
ing light remains on, have a Yamaha dealer
check the electrical circuit.
Engine trouble warning light “ ”
This warning light comes on or flashes if a prob-
lem is detected in the electrical circuit monitor-
ing the engine. If this occurs, have a Yamaha
dealer check the vehicle.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the start switch is pushed, or if the warn-
ing light remains on, have a Yamaha dealer
check the electrical circuit.
EAS2GC1031ENGINE STOP SWITCH
The engine stop switch “1” is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
After the engine stops, the multi-function dis-
play will go off and the power supply to the ECU
(Electronic Control Unit) will be cut off if the en-
gine stop switch is pushed and held.
TIP
The multi-function display will go off after one
minute if the engine stop switch is not pushed.
EAS2GC1032START SWITCH
The start switch “1” is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.
EAS2GC1033CLUTCH LEVER
The clutch lever “1” is located on the left han-
dlebar. The clutch lever disengages or engag-
es the clutch.
Pull the clutch lever toward the handlebar to
disengage the clutch, and release the lever to
engage the clutch.
1. Engine trouble warning light “ ”
2. Fuel level warning light “ ”
12