2016 YAMAHA WR 450F engine oil

CHASSIS
3-31
• When refilling, be careful that water does not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
EAS2GC1110ADJUSTING THE DRIVE CHAIN SLACKECA
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
1. 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.
2. Shift the transmission into the neutral posi-
tion.
3. Pull the drive chain up above the drive chain guide installation bolt with a force of about
50 N (5.0 kgf, 36 lbf).
4. Check: • Drive chain slack “a”
Out of specification  Regulate.
TIP
Measure drive chain slack between the drive
chain guide and the bottom of the chain as
shown. 5. Adjust:
• Drive chain slack
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a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn the adjusting bolt “3” in direction “a” or “b” until the specified drive chain slack is ob-
tained.
TIP
• To maintain the proper wheel alignment, ad-just both sides evenly.
• Push the rear wheel forward to make sure that
there is no clearance between the swingarm
end plates and the ends of the swingarm.
d. Tighten the locknut.
e. Tighten the wheel axle nut.
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EAS2GC1111CHECKING THE FRONT FORK LEGS
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: • Inner tubeDamage/scratches  Replace.
• Front fork leg (s) Oil leaks between inner tube and outer tube
 Replace the oil seal.
Drive chain slack (on a suitable
stand)
50.0–60.0 mm (1.97–2.36 in)
a
Direction “a”The drive chain slack decreases.
Direction “b” The drive chain slack increases.
Locknut21 Nm (2.1 m·kgf, 15 ft·lbf)
Wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf)
1
32
a
b
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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”.
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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)
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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

CHASSIS
3-39
EAS2GC1127LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained prop-
erly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only kerosene to
clean the drive chain. Wipe the drive chain dry
and thoroughly lubricate it with engine oil or
chain lubricant that is suitable for O-ring chains.
Do not use any other lubricants on the drive
chain since they may contain solvents that
could damage the O-rings.
EAS2GC1128LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
EAS2GC1129CHECKING THE CHASSIS FASTENERS
Make sure that all nuts, bolts, and screws are
properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES”
on page 2-17.Recommended lubricant
Chain lubricant suitable for O-
ring chains
Recommended lubricant Lithium-soap-based grease

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)
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Screw (throttle cable housings)3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
64
1 b
c
3
64
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ENGINE REMOVAL
6-3
Removing the electronic parts
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.
Air filter case cover
1 Rectifier/regulator 1
2ECU 1
3 Ignition coil 1
4 Neutral switch 1
5 AC magneto coupler 1 Disconnect.
6 Crankshaft position sensor coupler 1 Disconnect.
7 Coolant temperature sens or coupler1 Disconnect.
For installation, reverse the removal proce-
dure.
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CAMSHAFT
6-16
EAS2GC1242CHECKING THE DECOMPRESSION SYS-
TEM
1. Check:• Decompression system
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a. Check that the decompressor cam “1”
moves smoothly.
b. Check that the decompressor lever pin “2” projects from the camshaft.
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EAS2GC1243INSTALLING THE CAMSHAFTS
1. Install:• Exhaust camshaft “1”
• Intake camshaft “2”
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a. Turn the crankshaft counterclockwise with a
wrench.
TIP
• Apply molybdenum disulfide oil to the cam-shafts.
• Apply the engine oil on the decompression
system.
b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the
crankcase cover. c. Fit the timing chain “3” onto both camshaft
sprockets and install the camshafts on the
cylinder head.
TIP
Make sure that the alignment mark “c” on the
exhaust camshaft sprocket and the alignment
mark “d” on the intake camshaft sprocket are
aligned with the edge of the cylinder head.
ECA
NOTICE
Do not turn the crankshaft during the cam-
shaft installation. Damage or improper
valve timing will result.
d. Install the clips, the camshaft caps and the bolts (camshaft cap).
TIP
• Before installing the clips, cover the cylinder head with a clean cloth to prevent the clips
from coming off into the cylinder head cavity.
• Apply the engine oil to the threads and con- tact surfaces.
• Tighten the bolts to the specified torque in two or three steps in the proper tightening se-
quence as shown.
ECA
NOTICE
The bolts (camshaft cap) must be tightened
evenly, or damage to the cylinder head,
camshaft caps, and camshaft will result.
1
2
Bolt (camshaft cap)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
ab
c
3
d
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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)
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4
5
78 9
610 11
12
12
20
1
14
16
13
15 19
18
17
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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.
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2
5
4
1
7
8
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