2016 YAMAHA WR 450F check engine

ENGINE
3-12
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EAS2GC1087CHECKING THE COOLANT CIRCULATORY
SYSTEM FOR LEAKS
1. Check:• Coolant level
2. Install: • Radiator cap tester “1”
• Adapter “2”
3. Activate the tester to apply the test pressure.
ECA
NOTICE
• Do not apply such a high pressure as ex- ceeds the test pressure.
• Make sure that a checkup after the cylin-
der head gasket is replaced is made after 3
minutes of warm-up.
• Make sure that coolant is filled up to the
upper level beforehand.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
4. Check:
• Pressure valueNo stay for 5 to 10 seconds at the test pres-
sure value  Correct.
• Radiator
• Radiator hose connections Coolant leaks  Correct or replace.
• Radiator hoses Bulges  Replace
EWA
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
EAS2GC1088ADJUSTING THE CLUTCH LEVER FREE
PLAY
1. Check:
• Clutch lever free play “a”Out of specification  Regulate.
Radiator cap tester
90890-01325
Mityvac cooling system tester kit YU-24460-A
Radiator cap tester adapter 90890-01352
Pressure tester adapter YU-33984
Radiator cap tester 90890-01325
Mityvac cooling system tester kit YU-24460-A
Radiator cap tester adapter 90890-01352
Pressure tester adapter YU-33984
Test pressure value 196 kPa (1.96 kg/cm
2, 27.9 psi)
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)

ENGINE
3-13
2. Adjust:• Clutch lever free play
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Handlebar side
a. Turn the adjuster “1” in direction “a” or “b”
until the specified clutch lever free play is ob-
tained.
TIP
If the clutch lever free play cannot be obtained
on the handlebar side, use the adjuster on the
clutch cable side.
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Clutch cable side
a. Slide the clutch cable cover.
b. Loosen the locknut “1”.
c. Turn the adjuster “2” in direction “a” or “b” until the specified clutch lever free play is ob-
tained.
d. Tighten the locknut “1”.
e. Return the clutch cable cover to its original position.
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EAS2GC1089ADJUSTING THE THROTTLE GRIP FREE
PLAY
TIP
Prior to adjusting throttle grip free play, the en-
gine idling speed should be adjusted.
1. Check:• Throttle grip free play “a”Out of specification  Regulate.
2. Adjust: • Throttle grip free play
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a. Loosen the locknut “1”.
b. Turn the adjuster “2” until the specified free
play is obtained.
c. Tighten the locknut.
EWA
WARNING
After adjusting the throttle grip free play,
turn the handlebar to the right and to the left
to ensure that this does not cause the en-
gine idling speed to change.
Direction “a”
Clutch lever free play is increased.
Direction “b” Clutch lever free play is decreased.
Direction “a” Clutch lever free play is increased.
Direction “b” Clutch lever free play is decreased.
Locknut4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
a
b
1
T R..
Throttle grip free play
3.0–6.0 mm (0.12–0.24 in)
Direction “a” Throttle grip free play is increased.
Direction “b” Throttle grip free play is decreased.
1
2 a
b

ENGINE
3-14
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EAS2GC1090LUBRICATING THE THROTTLE CABLE
1. Remove:• Cover (throttle cable cap) “1”
• Cover (grip cap) “2”
• Throttle grip cap “3”
2. Lubricate: • Throttle cable end “a”
3. Install: • Throttle grip cap
• Screw (throttle grip cap) 4. Install:
• Cover (grip cap)
• Cover (throttle cable cap)
EWA
WARNING
Check that the throttle grip moves smooth-
ly. If this does not move smoothly, correct
the installed positions.
EAS2GC1091CLEANING THE AIR FILTER ELEMENT
1. Remove:• Fuel tank cap cover “1”Refer to “FUEL TANK CAP” on page 1-20.
• Air filter case cover “2”
TIP
Loosen the quick fastener screw “3” and re-
move the air filter case cover.
2. Remove:
• Air filter mounting bolt “1”
• Air filter element “2”
• Air filter guide “3” (from the air filter element)
3. Wash: • Air filter element
EWA
WARNING
Do not use gasoline or organic (acid/alka-
line) volatile oil for washing.
TIP
After washing the element with air filter cleaner
or kerosene, squeeze and dry it completely.
ECA
Recommended lubricantLithium-soap-based grease
Screw (throttle grip cap) 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
1
2
b
a
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1
2
3
3
3
13
2

ENGINE
3-15
NOTICE
Do not twist the element when squeezing
the element.
4. Check:• Air filter element
Damage  Replace.
5. Yamaha foam air filter oil or other quality foam air filter oil.
TIP
Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:• Air filter guide “1” (to the air filter element)
• Air filter element “2”
• Air filter mounting bolt “3”
7. Install: • Air filter case cover “1”
TIP
Align the air filter case cover groove “a” with the
air filter case edge “b”. 8. Install:
• Fuel tank cap cover
EAS2GC1092CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body jointRefer to “CHECKING THE THROTTLE
BODY JOINT” on page 8-10.
EAS2GC1093CHECKING THE BREATHER HOSES
1. Check:• Breather hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
ECA
NOTICE
Make sure the cylinder head breather hose
is routed correctly.
EAS2GC1094CHECKING THE EXHAUST SYSTEM
1. Remove:
• Exhaust pipe protector
2. Check: • Exhaust pipe 1
• Exhaust pipe 2
• SilencerCrack/damage  Replace.
Refer to “ENGINE REMOVAL” on page 6-1.
• Exhaust gas Leaks  Replace the gasket.
Refer to “ENGINE REMOVAL” on page 6-1.
Oil application quantify
50 g
Air filter mounting bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
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31
2
a
b
1
1

ENGINE
3-16
3. Check:• Tightening torques
4. Install: • Exhaust pipe protector
EAS2GC1095CHECKING THE FUEL LINE
1. Remove:• Seat
• Side cover (left/right)
• Air scoop (left/right)Refer to “GENERAL CHASSIS” on page 5-
1.
• Fuel tank Refer to “FUEL TANK” on page 8-1.
2. Check:
• Fuel hose “1”Crack/damage  Replace.
Loose connection  Connect properly. 3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 8-1.
• Air scoop (left/right)
• Seat
• Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-
1.
EAS2GC1096CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle upright on a level surface.
2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait
about 1 minute.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
3. Check:
• Oil levelMake sure that the engine oil level is above
the minimum level mark “a” shown for the oil
level check window “1”, and that the engine
oil does not come out by removing the oil
check bolt “2”.
The minimum level mark “a” or below  Add
the engine oil until its level exceeds the min-
imum level mark “a”.
Engine oil coming out of the oil check bolt 
Drain it until its last drop is out.
ECA33DD018
Exhaust pipe bolt 1 and nut “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe 1 and exhaust pipe
2 bolt “2” 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Exhaust pipe 2 and silencer bolt
“3” 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer and silencer bracket bolt
“4” 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe protector screw 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
T R..
2
1
4
3
T R..
1
12
a

ENGINE
3-17
NOTICE
• Since engine oil also lubricates the clutch, the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives.
• Do not allow foreign material to enter the
crankcase.
EAS2GC1097CHANGING THE ENGINE OIL
Stand the vehicle upright on a level surface.
1. Start the engine, warm this up for 3 minutes, and then stop the engine and wait about 5
minutes.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
2. Place an oil pan under the drain bolt.
3. Remove:• Engine guard “1”
• Oil filler cap “2”
• Drain bolt (with gasket) “3” 4. If the oil filter element is also to be replaced,
perform the following procedure.
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a. Remove the oil filter element cover “1” and oil filter element “2”.
b. Replace the O-ring “3”.
c. Install the new oil filter element and the oil fil- ter element cover.
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5. To check the oil strainer, perform the follow-ing procedure.
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a. Remove the oil strainer “1”.
b. Check the oil strainer.Damage  Replace.
Clogging due to dirt  Wash with kerosene.
Recommended brand
YAMALUBE
Type SAE 10W-40, SAE 10W-50, SAE
15W-40, SAE 20W-40 or SAE
20W-50
Recommended engine oil grade API service SG type or higher,
JASO standard MA
Oil filter element cover bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
12
3
1
3 2
New
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ENGINE
3-18
c. Replace the O-ring “2”.
d. Install the oil strainer.
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6. Install:•Gasket
• Drain bolt
7. Pour the specified amount of engine oil into the oil filler cap hole.
8. Install: • Oil filler cap
9. Check: • Oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-16. 10.Check:
• Engine oil pressure
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a. Slightly loosen the oil pressure check bolt “1”.
EWA
WARNING
When the engine is started with the check
bolt removed, oil will spout; therefore, al-
ways loosen it before the checkup.
b. Start the engine and keep it idling until oil starts to seep from the oil pressure check
bolt.
EWA
WARNING
Always keep the engine idling speed during
the checkup without increasing the engine
speed.
ECA
NOTICE
If no engine oil seeps out after one minute,
immediately turn the engine off so it will not
seize.
c. If no engine oil seeps out, check the engine oil for leaks, and t he engine oil passage and
the oil pump for damage.
d. Check the oil pressure again.
e. Tighten the oil pressure check bolt.
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Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drain bolt 20 Nm (2.0 m·kgf, 14 ft·lbf)
Engine oil quantity Oil change 0.67 L (0.71 US qt, 0.59 Imp.qt)
With oil filter removal 0.69 L (0.73 US qt, 0.61 Imp.qt)
Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt)
1
2New
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New
T R..
Oil pressure check bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
T R..

ENGINE
3-20
EAS2GC1099ADJUSTING THE VALVE CLEARANCE
TIP
• This section is intended for those who have basic knowledge and skill concerning the ser-
vicing of Yamaha motorcycles (e.g., Yamaha
dealers, service engineers, etc.). Those who
have little knowledge and skill concerning ser-
vicing are requested not to undertake inspec-
tion, adjustment, disassembly, or reassembly
only by reference to this manual. It may lead
to servicing trouble and mechanical damage.
• Make sure that the valve clearance is checked or adjusted while the engine is cold
(at room temperature).
• While the valve clearance is checked or ad- justed, make sure that the piston is positioned
in the top dead center (TDC).
1. Remove: • Seat
• Side cover (left/right)
• Air scoop (left/right)Refer to “GENERAL CHASSIS” on page 5-
1.
• Fuel tank
Refer to “FUEL TANK” on page 8-1.
•ECU
2. Remove:
• Spark plug
• Cylinder head coverRefer to “CAMSHAFT” on page 6-11.
3. Remove: • Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
• O-ring 4. Check:
• Valve clearanceOut of specification  Regulate.
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a. Turn the crankshaft counterclockwise with a
wrench.
b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the
crankcase cover.
TIP
Check that the alignment mark “c” on the cam-
shaft sprocket and the alignment mark “d” on
the intake camshaft sprocket are aligned with
the edge of the cylinder head.
c. Measure the valve clearance “e” using a
thickness gauge “1”.
TIP
Record the measured reading if the clearance
is incorrect.
12
Valve clearance (cold)Intake 0.13–0.20 mm (0.0051–0.0079 in)
Exhaust 0.18–0.25 mm (0.0071–0.0098 in)
ab
d
c