2016 YAMAHA WR 450F clutch

CLUTCH
6-41
EAS2GC1265
CLUTCH
Removing the clutch
OrderPart name Q’tyRemarks
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Brake pedal Refer to “ENGINE REMOVAL” on page 6-1.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3 O-ring 1
4 Clutch spring 6
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8Washer 1
9 Bearing 1
10 Ball 1
11 Push rod 2 1
12 Friction plate 1 3
13 Clutch plate 1 4 Thickness:2.0 mm (0.079 in)
LS
New
New
New
2
3
4
5
78 9
610 11
12
12
20
1
14
16
13
15 19
18
17
T.R.
T.R.
T.R.
T.R.
LT
(2) (5) (6)

CLUTCH
6-42
14 Friction plate 25 Identification color (purple)
15 Clutch plate 2 3 Thickness:1.6 mm (0.063 in)
16 Cushion spring 1
17 Clutch boss 1
18 Thrust washer 1
19 Primary driven gear 1
20 Push lever shaft 1
For installation, reverse the removal proce-
dure.
Removing the clutch
Order Part name Q’tyRemarks
LS
New
New
New
2
3
4
5
78 9
610 11
12
12
20
1
14
16
13
15 19
18
17
T.R.
T.R.
T.R.
T.R.
LT
(2) (5) (6)

CLUTCH
6-43
Removing the right crankcase cover
OrderPart name Q’tyRemarks
Engine guard Refer to “ENGINE REMOVAL” on page 6-1.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
Brake pedal Refer to “ENGINE REMOVAL” on page 6-1.
Clutch cover Refer to “CLUTCH” on page 6-41.
1 Oil filter element cover 1
2 Oil filter element 1
3 Radiator pipe 2 1
4 Kickstarter lever 1
5 Right crankcase cover 1
6 Gaskets 1
7 Dowel pin 2
8Collar 1
For installation, reverse the removal proce-
dure.
T.R.
LS
New
New
67
2
5
4
1
7
8
New
3
LS
New
New
LS
LS
NewNew
LT
LS

CLUTCH
6-44
EAS2GC1266REMOVING THE CLUTCH
1. Remove:• Clutch boss nut “1”
• Conical washer “2”
• Clutch boss “3”
TIP
While holding the clutch boss with the clutch
holder “4”, loosen the clutch boss nut.
EAS2GC1267CHECKING THE FRICTION PLATES
1. Check:• Friction plate
Damage/wear  Replace the friction plates
as a set.
2. Measure:
• Friction plate thicknessOut of specification  Replace the friction
plates as a set.
TIP
Measure it at four points on the friction plate.
EAS2GC1268
CHECKING THE CLUTCH PLATES
1. Check: • Clutch plate
Damage  Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage(with a surface plate and thickness gauge
“1”)
Out of specification  Replace the clutch
plates as a set.
EAS2GC1269CHECKING THE CLUTCH SPRINGS
1. Check: • Clutch springDamage  Replace the clutch springs as a
set.
2. Measure: • Clutch spring free lengthOut of specification  Replace the clutch
springs as a set.
Universal clutch holder
90890-04086
Universal clutch holder YM-91042
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.85 mm (0.112 in)
3 4
12
Warpage limit
0.10 mm (0.004 in)
Clutch spring free length 50.00 mm (1.97 in)
Limit 47.50 mm (1.87 in)

CLUTCH
6-45
EAS2GC1270CHECKING THE CLUTCH HOUSING
1. Check:• Clutch housing dogs “a”Damage/pitting/wear  Deburr the clutch
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch ho using dogs will cause er-
ratic clutch operation.
EAS2GC1271CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear  Replace the clutch
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS2GC1272CHECKING THE PRESSURE PLATE
1. Check: • Pressure plateCrack/damage  Replace.
EAS2GC1273CHECKING THE PUSH LEVER SHAFT
1. Check:
• Push lever shaftWear/damage  Replace.
EAS2GC1274CHECKING THE CLUTCH PUSH RODS
1. Check:
• Push rod 1 “1”
• Bearing “2”
• Washer “3”
• Push rod 2 “4”
•Ball “5”
Cracks/damage/wear  Replace.
2. Measure: • Push rod 2 bending limit
Out of specification  Replace.
EAS2GC1275CHECKING THE PRIMARY DRIVE GEAR
1. Check:
• Primary drive gearDamage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Re-
place the primary drive and primary driven
gears as a set.
2. Check: • Primary-drive-gear-to-primary-driven-gear free play
Free play exists  Replace the primary
drive and primary driven gears as a set.
a
Push rod bending limit 0.10 mm (0.004 in)

CLUTCH
6-46
EAS2GC1276CHECKING THE PRIMARY DRIVEN GEAR
1. Check:• Primary driven gearDamage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Re-
place the primary drive and primary driven
gears as a set.
EAS2GC1277INSTALLING THE OIL SEAL
1. Install: • Oil seal “1”
• Washer “2”
• Circlip “3”
TIP
• Apply the lithium-soap-based grease on the
oil seal lip.
• Install the oil seal in parallel with its manufac-
ture's marks or numbers facing inward.
EAS2GC1278INSTALLING THE RIGHT CRANKCASE
COVER
1. Install: • Dowel pin “1”
• O-rings “2”
• Collar “3”
• Gasket “4”
TIP
Apply the lithium-soap-based grease on the O-
ring.
2. Install:
• Right crankcase cover “1” • Right crankcase cover bolt “2”
TIP
• Apply the engine oil on the impeller shaft end.
• When installing the crankcase cover onto the
crankcase, make sure that the impeller shaft
end “3” aligns with the balancer end slot “4”.
• Tighten the right crankcase cover bolts in
stages and in a crisscross pattern.
EAS2GC1279INSTALLING THE CLUTCH
1. Install:
• Push lever shaft “1”
TIP
• Apply the lithium-soap-based grease on the oil seal lip.
• Before installation, apply the engine oil to the
push lever shaft sliding surface.
New
New
3
2
1
LS
New
New
1
1
4
2
New
New
3
LS
Right crankcase cover bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
1 2
1

CLUTCH
6-47
2. Install:• Primary driven gear “1”
• Thrust washer “2”
• Clutch boss “3”
TIP
Apply the engine oil on the primary driven gear
inner circumference.
3. Install:• Conical washer “1”
• Clutch boss nut “2”
ECA1DX1020
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is
fastened together.
TIP
• Install the conical washer with its convex sur-face “a” outward.
• Apply engine oil to the threads and contact surface of the clutch boss nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Use the clutch holding tool “3” to hold the
clutch boss. 4. Install:
• Friction plate 1 “1”
• Clutch plate 2 “2”
• Cushion spring “3”
• Friction plate 2 “4”
• Clutch plate 1 “5”
TIP
• Install the clutch plates and friction plates al-
ternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• From the clutch boss side, install the friction
plates in order: friction plate 1  2, friction
plate 2 (identification color: purple)  5, and
friction plate 1  1.
• From the clutch boss side, the clutch plate in order: clutch plate 2 (thickness: 1.6 mm)  3,
and clutch plate 1 (thickness: 2.0 mm)  4.
• Apply the engine oil on the friction plates and
clutch plates.
Clutch boss nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
Universal clutch holder 90890-04086
Universal clutch holder YM-91042
New
T R..
a. Identification color
a2
3
21
1
314
225
1 4
5
a
4 53
4
2
1

CLUTCH
6-48
5. Install:• Bearing “1”
• Washer “2”
• Circlip “3” To push rod 1 “4”.
TIP
Apply the engine oil on the bearing and washer.
6. Install:• Push rod 2 “1”
•Ball “2”
• Push rod 1 “3”
TIP
Apply the engine oil on the push rod 1, 2 and
ball.
7. Install:
• Pressure plate “1” 8. Install:
• Clutch spring
• Clutch spring bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
9. Install:• O-ring “1”
TIP
Apply the lithium-soap-based grease to the O-
ring.
10.Install:• Clutch cover “1”
• Clutch cover bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
NewClutch spring bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
New
T R..