2016 YAMAHA WR 450F ABS

REAR SHOCK ABSORBER ASSEMBLY
5-60
Disassembling the relay arm
OrderPart name Q’tyRemarks
1 Relay arm 1
2 Connecting arm 1
3Collars 3
4Oil seals 6
5Washers 8
6 Bearing 6
For assembly, reverse the disassemble pro-
cedure.
5
3
5
6
165
4
5
5
4
56
6
5
4
3
2
4
6
6
3
4
4
T.R.80 Nm (8.0 mlbf)
kgf, 58 ft
M
M
M
M
M
M M

REAR SHOCK ABSORBER ASSEMBLY
5-61
EAS2GC1208HANDLING THE REAR SHOCK ABSORBEREWA
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure that you understand the following in-
formation. The manufacturer cannot be held
responsible for property damage or person-
al injury that may result from improper han-
dling of the rear shock absorber.
• Do not tamper or attempt to open the rear shock absorber.
• Do not subject the rear shock absorber to an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.
EAS2GC1209DISPOSING OF A REAR SHOCK ABSORB-
ER
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA
WARNING
• Wear protective glasses to prevent your
eyes from damage due to possible gas or
metal chips scattered.
• To dispose of a damaged or a worn-out rear shock absorber, take the unit to your
Yamaha dealer for this disposal proce-
dure.
EAS2GC1210REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:• Rear shock absorber assembly lower bolt
“1”
TIP
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly
EAS2GC1211REMOVING THE BEARING
1. Remove:• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer
race and remove the stopper ring.
1
1

REAR SHOCK ABSORBER ASSEMBLY
5-62
2. Remove:• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1212CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
•Spring
Damage/wear  Replace. • Spring guide
Damage/wear  Replace.
• Bearing
Damage/wear  Replace.
•Bolts Bends/damage/wear  Replace.
EAS2GC1213CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
2. Check: • Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check: • Oil sealsDamage/pitting  Replace.
EAS2GC1214INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install: • Bearing “1”
• Washer “2”
• Oil seals “3” (to relay arm “4”)
1
Recommended lubricantMolybdenum disulfide grease
Installed depth “a” 0 mm (0 in)
New
3
3
43
2 2
2 2
a
1 1 1

REAR SHOCK ABSORBER ASSEMBLY
5-63
3. Install:• Bearing “1”
• Oil seals “2” (to connecting arm “3”)
EAS2GC1215INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY
1. Lubricate:• Bearing (lower side)
•Dust seal
•Collars
• Bushing
ECA
NOTICE
Do not apply the grease to the bearing outer
race because it will wear the rear shock ab-
sorber surface on which the bearing is
press fitted.
2. Lubricate:• O-ring
3. Install: • Bearing
• Stopper ring (to rear shock absorber assembly (upper
side))
TIP
• Install the bearing parallel until the stopper ring groove appears by pressing its outer
race.
• After installing the stopper ring, push back the
bearing unit it contacts the stopper ring. 4. Install:
• Bearing “1”
• Bushing “2”
• Collar “3”
• Dust seal “4”(to rear shock absorber assembly (lower
side))
TIP
Install the dust seals with their lips facing in-
ward.
5. Lubricate:
• Connecting arm and frame bolt
• Relay arm and connecting arm bolt
• Relay arm and swingarm bolt(circumference and threaded portion)
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly lower bolt
6. Install: • Rear shock absorber assembly
TIP
• When installing the rear shock absorber as-sembly, lift up the swingarm.
• Install the rear shock absorber assembly up- per bolt, and connecting arm bolt (frame side)
from the right.
• Install the rear shock absorber assembly low- er bolts, connecting arm bolt (relay arm side),
and relay arm bolt (swingarm side) from the
left.
Installed depth “a”
0 mm (0 in)
Recommended lubricant Molybdenum disulfide grease
Recommended lubricant Lithium-soap-based grease
New
3
a
1
1 2
a
2
New
Installed depth “a” 4.25 mm (0.17 in)
Recommended lubricant Molybdenum disulfide grease

REAR SHOCK ABSORBER ASSEMBLY
5-64
7. Tighten:• Rear shock absorber assembly upper bolt
• Connecting arm bolt (frame side)
• Connecting arm bolt (relay arm side)
• Relay arm bolt (swingarm side)
• Rear shock absorber assembly lower bolt Rear shock absorber assembly
upper bolt
56 Nm (5.6 m·kgf, 41 ft·lbf)
Connecting arm bolt (frame side) 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (relay arm
side) 80 Nm (8.0 m·kgf, 58 ft·lbf)
Relay arm bolt (swingarm side) 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear shock absorber assembly
lower bolt 53 Nm (5.3 m·kgf, 38 ft·lbf)
T R..
T R..
T R..
T R..
T R..

ENGINE REMOVAL
6-1
EAS2GC1225
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.
EAS2GC1226
ENGINE REMOVAL
Removing the exhaust pipe
OrderPart name Q’tyRemarks
Refer to “INSTALLING THE EXHAUST
PIPE AND MUFFLER” on page 6-9.
Side cover (right) Refer to “GENERAL CHASSIS” on page 5-1.
Rear shock absorber assembly lower bolt Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
Connecting arm bolt (relay arm side) Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
Starter motor Refer to “ELECTRIC STARTER” on page 6-
36.
1 Silencer clamp 1 Loosen.
2 Silencer 1
3 Exhaust pipe 2 clamp 1 Loosen.
105
9
26
1 6 6
3
8 4
7
(4)
(6)
30 Nm (3.0 m kgf, 22 ft Ibf)T
.R.
30 Nm (3.0 m kgf, 22 ft Ibf)T.R.
New
New
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.
20 Nm (2.0 m kgf, 14 ft Ibf)T.R.New
LT
LT
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.9 Nm (0.9 m kgf, 6.5 ft Ibf)T .R.
5 Nm (0.5 m kgf, 3.6 ft Ibf)T.R.
T
.R.*kgf
7 Nm (0.7 m , 5.1 ft lbf)
10 Nm (1.0 m kgf, 7.2 ft Ibf)
*

ENGINE REMOVAL
6-6
EAS2GC1227REMOVING THE SILENCER
1. Remove:• Rear shock absorber assembly lower bolt “1”
• Connecting arm bolt (relay arm side) “2”
• Silencer “3”
TIP
Move the rear shock absorber to the left side of
the chassis, and remove the silencer.
EAS2GC1228REMOVING THE EXHAUST PIPE 2
1. Remove: • Starter motor
Refer to “ELECTRIC STARTER” on page 6-
36.
• Exhaust pipe 2
TIP
Put the Exhaust pipe 2 into the state as shown
by moving this, and then remove it.
EAS2GC1229REMOVING THE DRIVE SPROCKET
1. Straighten the lock washer tab.
2. Remove:
• Nut (drive sprocket) “1”
• Lock washer “2”
TIP
Loosen the nut while applying the rear brake.
3. Remove:• Drive sprocket “1”
• Drive chain “2”
TIP
Remove the drive sprocket together with the
drive chain.
1 2
3

TROUBLESHOOTING
10-3
Cooling system
1. Coolant• Low coolant level
2. Radiator • Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump • Damaged or faulty water pump
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
Fuel system
1. Throttle body • Damaged or loose throttle body joint
2. Air filter • Clogged air filter element
Chassis
1. Brake(s) • Dragging brake
Electrical system
1. Spark plug • Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system • Faulty ECU
• Faulty coolant temperature sensor
EAS2GC1417OVERCOOLING
Cooling system
1. Coolant temperature sensor• Faulty coolant temperature sensor
EAS2GC1418POOR BRAKING PERFORMANCE
Chassis
1. Brake(s)• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Defective master cylinder kit
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS2GC1419FRONT FORK OIL LEAKING
Chassis
1. Front fork• Bent, damaged, or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
EAS2GC1420FAULTY FRONT FORK LEGS
Chassis
1. Front fork • Bent or damaged inner tube
• Bent or damaged outer tube
• Broken fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS2GC1421UNSTABLE HANDLING
Chassis
1. Handlebar• Bent or improperly installed handlebar
2. Steering head components • Improperly installed upper bracket
• Improperly installed lower bracket(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg (s) • Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm • Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly (-ies) • Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire (s) • Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear