2016 YAMAHA WR 450F light

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..

STEERING HEAD
5-53
EAS2GC1203
STEERING HEAD
Removing the lower bracket
OrderPart name Q’tyRemarks
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-37.
Use a suitable stand to raise the front wheel
off the ground.
Headlight assembly/multi -function meter/front
fender Refer to “GENERAL
CHASSIS” on page 5-1.
Handlebar Refer to “HANDLEBAR” on page 5-33.
1 Front fender 1
2 Steering stem nut 1
3 Front fork leg (s) 2 Refer to “FRONT FORK” on page 5-40.
4 Upper bracket 1
5 Steering ring nut 1
6 Lower bracket 1
7 Bearing race cover 1
8 Upper bearing 1
9 Bearing (lower side) 1
10 Bearing races 2
2
4
5
7
3
(2) (2)
(2)
(2)
(2)
1
6
8
9
10
LS
LS
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.3.8 Nm (0.38 mlbf)
kgf, 2.8 ft
T
.R.3.8 Nm (0.38 mlbf)
kgf, 2.8 ft
T
.R.9 Nm (0.9 mlbf)
kgf, 6.5 ft
T
.R.7 Nm (0.7 mlbf)
kgf, 5.1 ftT
.R.7 Nm (0.7 mlbf)
kgf, 5.1 ft
T
.R.10 Nm (1.0 mlbf)
kgf, 7.2 ft
T
.R.145 Nm (14.5 mlbf)
kgf, 105 ft
T
.R.38 Nm (3.8 mlbf)
kgf, 27 ft
7 Nm (0.7 m
lbf)
kgf, 5.1 ft
*
*

ENGINE REMOVAL
6-7
EAS2GC1230REMOVING THE ENGINE
1. Remove:• Pivot shaft “1”
TIP
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.
2. Remove:• Engine “1”
From the right side.
TIP
• Make sure that the couplers, the hoses, and the cables are disconnected.
• Lift up the engine, and remove this from its
lower part toward the right of the chassis.
EAS2GC1231CLEANING THE SPARK ARRESTEREWA
WARNING
• Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
• Do not start the engine when cleaning the
exhaust system.
1. Remove: • Muffler cap screws “1”
2. Remove: • Spark arrester bolts “1”
3. Remove: • Tail pipe “1”
• Tail pipe gasket “2”
• Spark arrester “3”Pull the spark arrester out of the muffler.
• Spark arrester gasket “4”
4. Clean: • Spark arresterTap the spark arrester lightly, then use a
wire brush to remove any carbon deposits.
1

CAMSHAFT
6-15
c. Install the dowel pins and the camshaft caps.
TIP
• Tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps.
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance.
d. Remove the camshaft caps and then mea- sure the width of the Plastigauge® “1”.
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5. Measure:• Camshaft journal diameter “a”Out of specification  Replace the cam-
shaft.
Within specification  Replace the cylinder
head and the camshaft caps as a set.
EAS2GC1240CHECKING THE TIMING CHAIN AND CAM-
SHAFT SPROCKET
1. Check: • Timing chain “1”
Damage/stiffness  Replace the timing
chain and camshaft as a set. 2. Check:
• Camshaft sprocketMore than 1/4 tooth wear “a”  Replace the
camshaft and the timing chain as a set.
EAS2GC1241CHECKING THE TIMING CHAIN TENSION-
ERS
1. Check: • Timing chain tensioner
Crack/damage  Replace.
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a. While pressing the tensioner rod lightly with
your fingers, use a thin screwdriver “1” to
wind the tensioner rod up fully clockwise.
b. When releasing the screwdriver by pressing lightly with your fingers, make sure that the
tensioner rod will come out smoothly.
c. If not, replace the tensioner assembly.
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Camshaft cap bolts 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Camshaft journal diameter 21.959–21.972 mm (0.8645–
0.8650 in)
T R..
1
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
a
b 1
2

CAMSHAFT
6-17
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2. Install:• Timing chain tensioner
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a. While pressing the tensioner rod lightly with
your fingers, use a thin screwdriver to wind
the tensioner rod up fully clockwise.
b. With the tensioner rod fully wound and the chain tensioner UP mark “a” facing upward,
install the gasket “1”, the timing chain ten-
sioner “2”, and the gasket “3”, and tighten
the bolt “4”.
c. Release the screwdriver, check that the ten- sioner rod comes out smoothly, and tighten
the gasket “5” and the cap bolt “6”.
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3. Turn:• Crankshaft
Counterclockwise several turns.
4. Check: • Top dead center (TDC) mark on the rotor
Align with the crankcase alignment mark.
• Camshaft match marks Align with the cylinder head surface.
Out of alignment  Adjust.
5. Install: • Timing chain guide (top side) “1”
• Cylinder head cover gasket “2”
• Cylinder head cover “3”
• Bolt (cylinder head cover) “4”
TIP
Before installation, apply the sealant to the cyl-
inder head cover gasket.
6. Install:• Cylinder head breather hose
• Spark plug
Bolt (timing chain tensioner)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tensioner cap bolt 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
3 48
7
1 5
26
E
T R..
T R..
Bolt (cylinder head cover)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Yamaha bond No. 1215 90890-85505
(Three bond No.1215®)
Spark plug 13 Nm (1.3m·kgf, 9.4 ft·lbf)
6
5
T R..
4
4
4 3
2 1
T R..

VALVES AND VALVE SPRINGS
6-30
5. To fasten the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face
hammer.
ECA
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
6. Lubricate:
• Adjusting pad “1”
• Valve lifter “2”
7. Install: • Adjusting pad
• Valve lifter
TIP
• Check that the valve lifter turns smoothly when rotated with your finger.
• Make sure that the valve lifter and the adjust- ing pad are reinstalled in their original posi-
tions.
E
1
2

CRANKCASE
6-72
EAS2GC1311DISASSEMBLING THE CRANKCASE
1. Separate:• Right crankcase
• Left crankcase
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a. Remove the crankcase bolts.
TIP
Loosen each bolt 1/4 of a turn at a time and af-
ter all the bolts are loosened, remove them.
b. Remove the right crankcase “1”.
TIP
• Place the crankcase with its left side down-ward and split it by inserting a screwdriver tip
into the splitting slit “a” in the crankcase.
• Lift the right crankcase horizontally while light-
ly patting the crankcase splitting slit and the
engine mounting boss using a soft hammer,
and leave the crankshaft and the transmission
with the left crankcase.
ECA33DD041
NOTICE
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If the cases do not
separate, check for a remaining case bolt or
fitting. Do not force. c. Remove the dowel pins and O-ring.
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EAS2GC1312REMOVING THE CRANKCASE BEARING
1. Remove:
• Bearing “1”
TIP
• Remove the bearing from the crankcase by pressing its inner race.
• Do not use the removed bearing.
EAS2GC1313CHECKING THE TIMING CHAIN, TIMING
CHAIN GUIDE, OIL STRAINER
1. Check:• Timing chainStiffness  Replace the camshaft sprocket,
timing chain and crankshaft sprocket as a
set.
2. Check: • Timing chain guide
Damage/wear  Replace
EAS2GC1314CHECKING THE CRANKCASE
1. Wash:
• Crankcase
TIP
• Wash the crankcase in a mild solvent.
• Remove any remaining gasket from the
crankcase mating surface.
2. Check: • CrankcaseCrack/damage  Replace.
1
a

CRANKCASE
6-73
• Oil delivery passagesObstruction  Blow out with compressed
air.
EAS2GC1315INSTALLING THE OIL SEAL
1. Install:
• Oil seal “1” (to left crankcase)
EAS2GC1316ASSEMBLING THE CRANKCASE
1. Install:• Bearing cover plate
TIP
• Install the bearing by pressing its outer race parallel.
• To prevent the bearing cover plate screw (crankshaft) “1” from becoming loose, crimp
the screw head periphery “a” into the concave
“b” using a punch etc. In so doing, take care
not to damage the screwdriver receiving hole
in the screw.
2. Apply: • Sealant(to the crankcase mating surface) 3. Install:
• Dowel pins “1”
• Crankcase “2”(to the left crankcase)
TIP
• Apply the lithium-soap-based grease on the
O-ring.
• Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer.
• When installing the crankcase, the connecting rod should be positioned at top dead center
(TDC).
• Tighten the bolts in a crisscross pattern in two
(2) stages, with 1/4 turn each.
Installed depth “a”
0.0–0.5 mm (0.00–0.02 in)
Bearing cover plate 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Bearing cover plate (crankshaft) 18 Nm (1.8 m·kgf, 13 ft·lbf)
New
1
a
T R..
a
b
1
1
Yamaha Bond No.121590890-85505
(Three Bond No.1215®)
Crankcase bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
3. 45 mm (1.77 in)
4. 60 mm (2.36 in)
5. 75 mm (2.95 in)
T R..
4 3
5
3
3
3
4 5
4
3
1
12