2016 YAMAHA WR 450F fuel

3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................. 3-1
INTRODUCTION ........................................................................................ 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ....................... .......................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 3-2
MAINTENANCE INTERVALS FOR COMPETITION USE ......................... 3-4
PRE-OPERATION INSPECTION AND MAINTENANCE ................................. 3-9
GENERAL INSPECTION AND MAINTENANCE........................................ 3-9
ENGINE .......................................................................................................... 3-10
CHECKING THE COOLANT LEVEL ........................................................ 3-10
CHECKING THE COOLING SYSTEM ..................................................... 3-10
CHANGING THE COOLANT.................................................................... 3-10
CHECKING THE RADIATOR CAP .......................................................... 3-11
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ....... 3-11
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-12
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-13
LUBRICATING THE THROTTLE CABLE ................................................ 3-14
CLEANING THE AIR FILTER ELEMENT................................................. 3-14
CHECKING THE THROTTLE BODY JOINT ............................................ 3-15
CHECKING THE BREATHER HOSES .................................................... 3-15
CHECKING THE EXHAUST SYSTEM............................. ........................ 3-15
CHECKING THE FUEL LINE ................................................................... 3-16
CHECKING THE ENGINE OIL LEVEL............................. ........................ 3-16
CHANGING THE ENGINE OIL ................................................................ 3-17
ADJUSTING THE ENGINE IDLING SPEED ......... ................................... 3-19
ADJUSTING THE VALVE CLEARANCE ................................................. 3-20
CLEANING THE SPARK ARRESTER ..................................................... 3-24
CHASSIS ........................................................................................................ 3-25
BLEEDING THE BRAKE SYST EM .......................................................... 3-25
CHECKING THE BRAKE HOSE .............................................................. 3-26
ADJUSTING THE FRONT BRAKE .......................................................... 3-26
ADJUSTING THE REAR BRAKE ............................................................. 3-27
CHECKING THE FRONT BR AKE PADS ................................................. 3-27
CHECKING THE REAR BRAKE PADS ........................... ........................ 3-29
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-30
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-30
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-31
CHECKING THE FRONT FORK LEGS ................................................... 3-31
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-32
CLEANING THE FRONT FORK OI L SEAL AND DUST SEAL ................ 3-32
AIR BLEEDING FROM FRONT FORK .................................................... 3-32
ADJUSTING THE FRONT FORK LEGS .................................................. 3-33
CHECKING THE SWINGARM OPERATION ........................................... 3-34
CHECKING THE REAR SUSPENSION ................................................... 3-34

PERIODIC MAINTENANCE
3-1
EAS2GC1074
PERIODIC MAINTENANCE
EAS2GC1075INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly ov erhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS2GC1076PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP
• From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER READ-
INGS
600 mi (1000
km) or 1 month 1800 mi
(3000
km) or 3 months 3000 mi
(5000
km) or 6 months
1* Fuel line • Check fuel hoses for cracks or dam-
age.
• Replace if necessary. 
2Spark plug
• Check condition.
• Adjust gap and clean. 
3*Valve clear-
ance • Check and adjust valve clearance
when engine is cold. 
4*Air filter ele-
ment • Clean with solvent and apply Yamaha
foam air filter oil or other quality foam
air filter oil.
• Replace if necessary. 
5*
Breather
system • Check ventilation hose for cracks or
damage and drain any deposits. 
6*Fuel injec-
tion • Adjust engine idling speed.

7Exhaust sys-
tem• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.

8Engine oil
• Change (warm engine before drain-
ing). 
9Engine oil fil-
ter element•Replace.

10Engine oil
strainer• Clean.


PERIODIC MAINTENANCE
3-6
COOLING SYSTEMCheck coolant lev-
el and leakage
Check radiator cap
operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS
AND BOLTS
Retighten Refer to “STARTING AND
BREAK-IN” on page 1-28.
AIR FILTER
Clean and lubri-
cate Use Yamaha foam air filter oil
or other quality foam air filter
oil.
Replace
OIL FILTER
Replace
ENGINE GUARD Replace Breakage
FRAME Clean and inspect
FUEL TANK, FUEL
PUMP
Clean and inspect
FUEL HOSE Inspect
Replace Every four years
ITEM
After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks

PRE-OPERATION INSPECTION AND MAINTENANCE
3-9
EAS2GC1079
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAS2GC1080GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
Coolant Check that coolant is filled up to the radiator cap.
Check the cooling system for leakage. 3-10 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage. 1-28
Engine oil Check that the oil level is correct. Check the crank-
case and oil line for leakage. 3-16 – 18
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly. 3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary. 3-13 – 14
Brakes Check the play of front brake and effect of front and
rear brake. 3-25 – 31
Drive chain Check drive chain slack and alignment. Check that
the drive chain is lubricated properly. 3-31
5-69 – 70
Wheels Check for excessive wear and tire pressure. Check
for loose spokes and have no excessive play. 3-36 – 37
Steering Check that the handlebar can be turned smoothly and
have no excessive play. 3-37 – 38
Front forks and rear
shock absorber Check that they operate smoothly and there is no oil
leakage.
3-31 – 36
Cables (wires) Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and
has no cracks. 3-15 – 16
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is
not loose. 5-10 – 11
Lubrication Check for smooth operation. Lubricate if necessary. 3-14
3-38 – 39
Bolts and nuts Check the chassis and engine for loose bolts and
nuts. 1-32 – 33
Lead connectors Check that the AC magneto, ECU and ignition coil are
connected tightly. 1-9 – 12
Settings Is the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?
4-1 – 8

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
T R..
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)
T R..
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
3-19
EAS2GC1098ADJUSTING THE ENGINE IDLING SPEED
TIP
• Because the air pressure is lower at high alti-tudes, the air-fuel mixture will become richer.
If the idling speed is low, turn the starter knob/
idle screw a few clicks counterclockwise to in-
crease the speed before the adjustment.
• Before adjusting the engine idling speed, make sure that the air filter element is not
clogged, the engine compression is proper,
and the throttle grip free play is proper.
• Adjust the engine idling speed with the starter
knob/idle screw pushed in completely.
1. Start the engine, and warm this up until the oil has reached the specified temperature.
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. Attach the pocket tester with temperature probe “1” to the oil drain bolt.
3. Install: • Digital tachometer
TIP
Get the high tension cord “1” of the ignition coil
pinched in the detector “a” of the digital tachom-
eter.
4. Measure:• Engine idling speed
Out of specification  Regulate.
5. Adjust: • Engine idling speed
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a. Turn the starter knob/idle screw “1” in the di- rection of “a” or “b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Oil temperature70–80 °C (158–176 °F)
Digital tachometer 90890-06760
Digital tachometer YU-39951-B
1
Engine idling speed 1900–2100 r/min
Direction “a” Engine idling speed  De-
creases.
Direction “b” Engine idling speed  In-
creases.
1
1
a
a
1
b
a