2016 YAMAHA WR 450F clutch
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CHASSIS
3-38
c. Turn the front fork to the right and left a few times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly,
remove the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 5-53.
d. Loosen the ring nut fully turn and then tight- en it to specification with a steering nut
wrench.
EWA
WARNING
Do not overtighten the lower ring nut.
e. Check the steering head for looseness or binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 5-53.
f. Install the washer “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install: • Upper bracketRefer to “STEERING HEAD” on page 5-53.
• Handlebar
Refer to “HANDLEBAR” on page 5-33.
EAS2GC1124CHECKING AND LUBRICATING THE CA-
BLES
The following procedure applies to all of the in-
ner and outer cables.
EWA
WARNING
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner ca-
bles as soon as possible.
1. Check:• Outer cableDamage Replace.
2. Check: • Cable operationRough movement Lubricate.
TIP
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
EAS2GC1125LUBRICATING THE LEVERS
1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
•Brake lever
• Clutch lever
EAS2GC1126LUBRICATING THE PEDAL
1. Lubricate the pivoting point and metal-to-
metal moving parts of the pedal.
Steering nut wrench
90890-01403
Exhaust flange nut wrench YU-A9472
Ring nut (initial tightening torque) 38 Nm (3.8 m·kgf, 27 ft·lbf)
Ring nut (final tightening torque) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T R..
T R..
1
Recommended lubricantEngine oil or a suitable cable lu-
bricant
Recommended lubricant Silicone grease
Recommended lubricant Lithium-soap-based grease
Recommended lubricant Lithium-soap-based grease
Page 185 of 426
HANDLEBAR
5-33
EAS2GC1193
HANDLEBAR
Removing the handlebar
OrderPart name Q’tyRemarks
1 Clutch cable 1 Disconnect.
2 Clutch switch 1
3 Clutch lever holder 1
4 Engine stop switch 1
5 Brake master cylinder 1
6 Throttle cable cap 1
7 Throttle cable (pull) 1 Disconnect.
8 Throttle cable (return) 1 Disconnect.
9 Right grip 1
10 Tube guide 1
11 Start switch 1
12 Left grip 1
13 Handlebar upper holder 2
14 Handlebar 1
Page 187 of 426
HANDLEBAR
5-35
EAS2GC1194REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:•Clutch switch “1”
TIP
Press the projection, and remove it from the
clutch lever assembly.
3. Remove:• Handlebar grip “1”
TIP
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
4. Remove:
• Throttle cable housings “1”
• Throttle grip “2”
TIP
While removing the throttle cable housing, pull
back the rubber cover “3”.
EAS2GC1195CHECKING THE HANDLEBAR
1. Check:• Handlebar
Bends/cracks/damage Replace.
EWA
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS2GC1196INSTALLING THE HANDLEBAR
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Damper “1”
• Lower handlebar holders“2” (temporarily)
• Handlebar “3”
• Upper handlebar holders “4”
TIP
• Install the lower handl ebar holders with them
side having the greater distance “a” from the
mounting bolt center facing forward.
• Installing the lower handlebar holders in the
reverse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• The upper handlebar holders should be in- stalled with the punch marks “b” facing for-
ward.
• When installing the handlebar, make sure that right and left marks “c” are in place identically
on both sides.
• Install the handlebar so that the projection “d” of the upper handlebar holders is positioned
at the mark on the handlebar as shown.
ECA
Upper handlebar holder bolt28 Nm (2.8 m·kgf, 20 ft·lbf)
T R..
Page 189 of 426
HANDLEBAR
5-37
5. Install:• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
•Clamp “4”
TIP
• The engine stop switch, the clutch lever, and the clutch lever holder should be installed ac-
cording to the dimensions shown.
• Pass the engine stop switch lead through the
middle of the clutch lever holder.
6. Install: • Right grip “1”
• Collar “2”Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the grip match mark “b” and tube guide slot “c”
form the angle as shown. 7. Install:
• Rubber cover “1”
• Throttle grip “2”
TIP
Apply the lithium-soap-based grease on the
throttle grip sliding surface.
8. Install:• Throttle cables “1”
TIP
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle-
bar.
9. Install:
• Throttle cable housings “1”
• Screw (throttle cable housings) “2”
EWA
Engine stop switch screw0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
Screw (throttle cable housings)3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
64
1 b
c
3
64
T R..
Page 190 of 426
HANDLEBAR
5-38
WARNING
After tightening the throttle cable housing
screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the
screws for adjustment.
10.Install:• Rubber cover “1”
• Cover (throttle cable housings) “2”
11.Install: • Start switch “1”
• Front brake master cylinder assembly “2”
• Front brake master cylinder holder “3”
• Bolt (brake master cylinder holder) “4”
•Clamp “5”
TIP
• Install the brake master cylinder holder with the “UP” mark facing up.
• Install in order for the top of the front brake master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.
12.Install: • Clutch cable “1”
TIP
Before installation, apply the lithium-soap-
based grease to the clutch cable end.
13.Adjust:• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LE-
VER FREE PLAY” on page 3-12.
Front brake master cylinder hold-
er bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T R..
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
2
5
1
4
3
4
1LS
Page 226 of 426
CLUTCH......................................................................................................... 6-41
REMOVING THE CLUTCH ...................................................................... 6-44
CHECKING THE FRICTION PLATES...................................................... 6-44
CHECKING THE CLUTCH PLATES ........................................................ 6-44
CHECKING THE CLUTCH SPRINGS...................................................... 6-44
CHECKING THE CLUTCH HOUSING ..................................................... 6-45
CHECKING THE CLUTCH BOSS ............................................................ 6-45
CHECKING THE PRESSURE PLATE ..................................................... 6-45
CHECKING THE PUSH LEVER SHAFT .................................................. 6-45
CHECKING THE CLUTCH PUSH RODS ................................................ 6-45
CHECKING THE PRIMARY DRIVE GEAR .............................................. 6-45
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 6-46
INSTALLING THE OIL SEAL ................................................................... 6-46
INSTALLING THE RIGHT CRANKCASE COVER ................................... 6-46
INSTALLING THE CLUTCH ..................................................................... 6-46
INSTALLING THE KICKSTAR TER LEVER ............................................. 6-49
KICKSTATER ................................................................................................. 6-50
REMOVING THE KICK SHA FT ASSEMBLY ........................................... 6-51
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 6-51
CHECKING THE KICK GEAR, KICK IDLE GEAR AND RATCHET
WHEEL .................................................................................................... 6-51
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 6-51
INSTALLING THE KICK IDLE GEAR ....................................................... 6-52
SHIFT SHAFT ................................................................................................. 6-53
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-54
REMOVING THE SEGMENT ................................................................... 6-54
CHECKING THE SHIFT SHAFT .............................................................. 6-54
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-54
CHECKING THE STOPPER LEVER ....................................................... 6-54
INSTALLING THE STOPPE R LEVER ............................. ........................ 6-55
INSTALLING THE SEGMENT.................................................................. 6-55
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 6-55
INSTALLING THE SHIFT SHAFT ............................................................ 6-56
INSTALLING THE SHIFT PEDAL ............................................................ 6-56
OIL PUMP AND BALANCER GEAR ............................................................. 6-57
REMOVING THE BALANCER ................................................................. 6-59
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT DRIVE GEAR, AND BALANCER WEIGHT GEAR .................................. 6-59
CHECKING THE BALANCER .................................................................. 6-59
CHECKING THE OIL PUMP .................................................................... 6-59
ASSEMBLING THE OIL PUMP ................................................................ 6-60
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 6-61
Page 227 of 426
GENERATOR AND STARTER CLUTCH....................................................... 6-63
REMOVING THE GENERATOR .............................................................. 6-65
CHECKING THE STARTER CLUTCH ..................................................... 6-65
INSTALLING THE STARTER CLUTCH ................................................... 6-66
INSTALLING THE GENERATOR............................................................. 6-67
CRANKCASE ................................................................................................. 6-69
DISASSEMBLING THE CRANKC ASE..................................................... 6-72
REMOVING THE CRANKCASE BEARING ............................................. 6-72
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL
STRAINER .............................................................................................. 6-72
CHECKING THE CRANKCASE ............................................................... 6-72
INSTALLING THE OIL SEAL ................................................................... 6-73
ASSEMBLING THE CRANKCASE........................................................... 6-73
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ............................... 6-74
REMOVING THE BALANCER SHAFT..................................................... 6-75
REMOVING THE CRANKSHAFT ASSEMBLY ........................................ 6-75
CHECKING THE CRANKSHA FT ASSEMBLY......................................... 6-75
INSTALLING THE CRANKSHA FT ASSEMBLY....................................... 6-76
TRANSMISSION ............................................................................................. 6-77
REMOVING THE TRANSMISSION ......................................................... 6-78
CHECKING THE SHIFT FORKS.............................................................. 6-78
CHECKING THE SHIFT DRUM ASSEMBLY ........................................... 6-79
CHECKING THE TRANSMISSION .......................................................... 6-79
INSTALLING THE TRANSMISSION ........................................................ 6-79
Page 231 of 426
ENGINE REMOVAL
6-4
Removing the engine
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
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.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 6-1.
Air filter case Refer to “THROTTLE BODY” on page 8-7.
Throttle body Refer to “THROTTLE BODY” on page 8-7.
Clutch cable Refer to “CLUTCH” on page 6-41.
Shift pedal Refer to “SHIFT SHAFT” on page 6-53.
Starter motor Refer to “ELECTRIC STARTER” on page 6-
36.
1 Engine guard 1
2 Brake pedal 1
3Spring 1
4 Cylinder head breather hose 1
New
New
LS
M
8
8
76
11
4 5
New
1
10
3 2 9
55 Nm (5.5 m kgf, 40 ft Ibf)T.R.