2016 YAMAHA WR 450F warning

CHASSIS
3-32
3. Hold the vehicle upright and apply the front brake.
4. Check:
• Front fork operationPush down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation  Correct or replace.
Refer to “FRONT FORK” on page 5-40.
EAS2GC1112CHECKING THE FRONT FORK PROTEC-
TOR GUIDE
1. Check:
• Protector guide “1”Out of specification  Replace.
TIP
The protector guide reaches the limit of its use
when it is worn down to the same height “a” as
of the outer tube circumference.
EAS2GC1113CLEANING THE FRONT FORK OIL SEAL
AND DUST SEAL
1. Remove:
•Protector
• Dust seal “1”
ECA
NOTICE
Be careful not to damage the dust seal and
the inner tube by a driver. 2. Clean:
• Dust seal “a”
• Oil seal “b”
TIP
• Clean the dust seal and oil seal after every
run.
• Apply lithium-soap-based grease on the inner
tube.
EAS2GC1114AIR BLEEDING FROM FRONT FORK
TIP
If the front fork initial movement feels stiff dur-
ing a run, relieve the front fork internal pres-
sure.
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove the air bleed screw “1” and release the internal pressure from the front fork.
1
a
1
LS
a
b

CHASSIS
3-33
3. Tighten:• Air bleed screw
EAS2GC1115ADJUSTING THE FRONT FORK LEGSEWA
WARNING
• Always adjust the left and right front forks evenly. If this is not done, the vehicle may
have poor stability.
• Securely support the vehicle so that there
is no danger of it falling over.
Rebound damping
ECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust: • Rebound damping
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a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
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Compression dampingECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:• Compression damping
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a. Turn the adjuster “1” in the direction of “a” or “b” to make an adjustment.
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Air bleed screw1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Direction “a” Rebound damping is increased (sus-
pension is harder).
Direction “b” Rebound damping is decreased (sus-
pension is softer).
Rebound damping adjusting posi-
tionsMaximumFully turned in
Standard 11 clicks out*
Minimum 20 clicks out*
* With the adjuster fully turned in
T R..
1
Direction “a” Compression damping is increased
(suspension is harder).
Direction “b” Compression damping is decreased
(suspension is softer).
Compression damping adjusting
positions Maximum Fully turned in
Standard 13 clicks out*
Minimum 20 clicks out*
* With the adjuster fully turned in
1
a b
ab
1

CHASSIS
3-34
EAS2GC1116CHECKING THE SWINGARM OPERATION
1. Check:• Swingarm smooth action
• Swingarm free playRefer to “SWINGARM” on page 5-65.
EAS2GC1117CHECKING THE REAR SUSPENSION
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. Check:• Rear shock absorber assemblyGas leaks/oil leaks  Replace the rear
shock absorber assembly.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
3. Check: • Rear shock absorber assembly smooth ac-tion
• Rear suspension link smooth action Sit astride the seat and shake your body up
and down several times to check whether
the rear shock absorber assembly operates
smoothly.
Unsmooth operation  Correct or replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
EAS2GC1118ADJUSTING THE REAR SHOCK ABSORB-
ER ASSEMBLY
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. Spring preload
ECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Remove:
• Rear frameRefer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
2. Adjust: • Spring preload
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a. Loosen the locknut “1”.
b. Loosen the adjuster “2” until there is some clearance between the spring and the ad-
juster.
c. Measure the spring free length “a”.
d. Turn the adjuster in the direction of “b” or “c” to make an adjustment.
Direction “b”Spring preload is increased (suspen-
sion is harder).
Direction “c” Spring preload is decreased (suspen-
sion is softer).
Spring preload adjusting positionsMinimum Position in which the spring is
turned in 1.5 mm (0.06 in) from
its free length.
Standard Position in which the spring is
turned in 12 mm (0.47 in) from its
free length.
Maximum Position in which the spring is
turned in 18 mm (0.71 in) from its
free length.

CHASSIS
3-37
2. Tighten:• SpokesUse a spoke nipple wrench “1” for tighten-
ing.
TIP
• Do not give a half turn (180 °) or more for one tightening.
• Make sure that tightening after a break-in is done until the initial looseness in nipples dis-
appears.
• Make sure that tightening is done in stages,
not at a time.
EAS2GC1121CHECKING THE WHEELS
1. Check: • Wheel(s)Damage/out-of-round  Replace.
EWA
WARNING
Never attempt to make any repairs to the
wheel.
TIP
After replacing a tire or a wheel, always bal-
ance the wheel.
EAS2GC1122CHECKING THE WHEEL BEARINGS
1. Check:
• Wheel bearingsRefer to “CHECKING THE FRONT WHEEL”
on page 5-5 and “CHECKING THE REAR
WHEEL” on page 5-10.
EAS2GC1123CHECKING AND ADJUSTING THE STEER-
ING HEAD
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  Adjust the steering
head.
3. Remove: • Handlebar
Refer to “HANDLEBAR” on page 5-33.
• Upper bracket Refer to “STEERING HEAD” on page 5-53.
4. Adjust: • Steering head
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a. Remove the washer “1”.
b. After loosening the ring nut “2” with a steer- ing nut wrench “3”, tighten it to the specified
torque.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly.
Spoke nipple wrench (6–7)
90890-01521
Spoke nipple wrench (6–7) YM-01521
Spokes 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
1
T R..
1
3
2

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”.
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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

ELECTRICAL SYSTEM
3-41
2. Attach:• Timing light “1”
• Digital tachometer “2”To the high tension code “3”.
3. Adjust: • Engine idling speedRefer to “ADJUSTING THE ENGINE
IDLING SPEED” on page 3-19.
4. Check: • Ignition timingCheck whether the alignment mark “a” on
the left crankcase cover is within the firing
range “b” on the rotor.
Incorrect firing range  Check rotor and
Crankshaft position sensor.
5. Install: • Timing mark accessing screwEAS2GC1133CHECKING AND CHARGING THE BATTERY
Refer to “CHECKING AND CHARGING THE
BATTERY” on page 9-69.
EAS2GC1134REPLACING THE HEADLIGHT BULBEWA
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
1. Remove:• Headlight unit bolt “1”
TIP
After you have removed the headlight unit
bolts, lift and remove the headlight unit.
2. Remove:
• Headlight coupler “1”
• Bulb cover “2”
3. Remove: • Headlight bulb “1”
Timing light
90890-03141
Timing light YU-03141
Digital tachometer 90890-06760
Digital tachometer YU-39951-B
Timing mark accessing screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
2
1
3
ba
T R..
11
1
2
1

CHASSIS
4-2
• Under a stony or a hard road condition, the tire pressure should be hi gher to prevent a flat
tire.
EAS2GC1140FRONT FORK SETTING
The front fork setting should be made depend-
ing on the rider’s feeli ng of an actual run and
the circuit conditions.
The front fork setting includes the following
three factors:
1. Setting of air spring characteristics • Change the fork oil amount.
2. Setting of spring preload • Change the spring.
3. Setting of damping force
• Change the compression damping force.
• Change the rebound damping force.The spring acts on the load and the damping
force acts on the cushion travel speed.
EAS2GC1141CHANGE IN AMOUNT AND CHARACTERIS-
TICS OF FORK OIL
Damping characteristic near the final stroke
can be changed by changing the fork oil
amount.
EWA
WARNING
Adjust the oil amount in 5 cm3 (0.2 US oz,
0.2 Imp.oz) increments or decrements. Too
small oil amount causes the front fork to
produce a noise at full rebound or the rider
to feel some pressure on his hands or body.
Alternatively, too large oil amount will
cause the air spring characteristics to have
a tendency to be stiffer with the consequent
deteriorated performance and characteris-
tics. Therefore, adjust the front fork within
the specified range.
EAS2GC1142SETTING OF SPRING AFTER REPLACE-
MENT
As the front fork setting can be easily affected
by the rear suspension, take care so that the
front and the rear are balanced (in position etc.)
when setting the front fork.
1. Use of soft spring
• Change the rebound damping force.Turn out one or two clicks.
• Change the compression damping force.
Turn in one or two clicks.
TIP
Generally a soft spring gives a soft riding feel-
ing. Rebound damping tends to become stron-
ger and the front fork may sink deeply over a
series of gaps.
2. Use of stiff spring• Change the rebound damping force.
Turn in one or two clicks.
• Change the compression damping force. Turn out one or two clicks.
Extent of adjustment
100–120 kPa (1.00–1.20 kgf/cm
2,
15–18 psi)
Standard oil amount 345 cm
3 (11.66 US oz, 12.14
lmp.oz)
Extent of adjustment 300–365 cm
3 (10.14–12.34 US
oz, 10.58–12.87 Imp.oz)
A. Air spring characteristics in relation to oil amount change
B. Load
C. Stroke
1. Max. oil amount
2. Standard oil amount
3. Min. oil amount

CHASSIS
4-4
TIP
• If the machine is new and after it is broken in, the same set length of the spring may change
because of the initial fatigue, etc. of the
spring. Therefore, be sure to make reevalua-
tion.
• If the standard figure cannot be achieved by adjusting the adjuster and changing the set
length, replace the spri ng with an optional one
and make readjustment.
EAS2GC1146SETTING OF SPRING AFTER REPLACE-
MENT
After replacement, be sure to adjust the spring
to the set length [sunken length 90–100 mm
(3.5–3.9 in)] and set it.
1. Use of soft spring
• Adjust to decrease rebound damping force to compensate for less spring load. Run with
the rebound damping force adjuster one or
two clicks turned out, and readjust it to suit
your preference.
2. Use of stiff spring • Adjust to increase rebound damping force to
compensate for greater spring load. Run
with the rebound damping force adjuster
one or two clicks turned in, and readjust it to
suit your preference.
TIP
Adjusting the rebound damping force will be fol-
lowed more or less by a change in the com-
pression damping force. For correction, adjust
to decrease compression damping force.
EWA
WARNING
When using a rear shock absorber other
than currently installed, use the one whose
overall length “a” does not exceed the stan-
dard as it may result in faulty performance.
Never use one whose overall length is
greater than standard.
EAS2GC1147REAR SHOCK ABSORBER SETTING
PARTS
• Rear shock spring “1”
TIP
• The I.D. mark “a” is marked at the end of the spring.
• Spring specification varies according to the
color of I.D. marks.
Length “a” of standard shock 462.5 mm (18.21 in)
Type Spring
rate N/ mm Part number
I.D.
Mark
SOFT 48
2GB-22212-10
(Blue) Black
50 2GB-22212-00
(Blue) Green
52 1SL-22212-40
(Blue) Yellow
B11-22212-00 (Yellow) Blue
54 1SL-22212-60
(Blue) Pink
B11-22212-10
(Yellow)
STD 56 1SL-22212-20
(Blue) White
B11-22212-20
(Yellow)
STIFF 58
1SL-22212-00
(Blue) Silver
B11-22212-30
(Yellow)
60 1SL-22212-80
(Blue) Brown
B11-22212-40
(Yellow)