2016 YAMAHA WR 450F light

TRANSMISSION
6-78
EAS2GC1323REMOVING THE TRANSMISSION
1. Remove:• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Shift cam “3”
• Shift fork 3 “4”
• Shift fork 2 “5”
• Shift fork 1 “6”
• Main axle “7”
• Drive axle “8”
• Collar “9”
TIP
• Remove assembly with the collar “9” installed to the crankcase.
• Make a note of the position of each part. Pay particular attention to the location and direc-
tion of shift forks.
• Remove the main axle and the drive axle all together by tapping the drive axle lightly with
a soft hammer.
EAS2GC1324CHECKING THE SHIFT FORKS
1. Check:• Shift fork cam follower “1”
• Shift fork pawl “2”Bends/damage/scoring/wear  Replace the
shift fork.
2. Check: • Shift fork guide barRoll the shift fork guide bar on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement  Replace the shift forks
and shift fork guide bar as a set.
1
4 6 2
53
8
7
9

TRANSMISSION
6-81
6. Install:• Shift fork 1 (L) “1”
• Shift fork 2 (C) “2”
• Shift fork 3 (R) “3”
• Shift cam “4”(to the main axle and the drive axle)
TIP
• Apply engine oil to the shift fork grooves.
• Apply engine oil to the shift cam groove and
the bearing contact surface.
• Mesh the shift fork 1 (L) with the 4th wheel gear “5” and shift fork 3 (R) with the 5th wheel
gear “7” on the drive axle.
• Mesh the shift fork 2 (C) with the 3rd pinion
gear “6” on the main axle. 7. Install:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Spring “3”
TIP
• Screw the spring into the shift fork guide bar lightly beforehand.
• Apply the engine oil on the shift fork guide
bars.
8. Check: • Operation of shift cam and shift fork
• Transmission operationUnsmooth operation  Repair.
3
12
EE
E
2
1 3
E

FUEL TANK
8-4
EAS2GC1344REMOVING THE FUEL SENDER
1. Remove:• Fuel sender
ECA
NOTICE
Do not drop the fuel sender or give it a
strong shock.
EAS2GC1345CHECKING THE FUEL SENDER
1. Disconnect:• Fuel pump coupler
• Fuel sender coupler
(from the wire harness)
2. Disconnect: • Starter motor lead
(from starter relay)
3. Remove: • Fuel tank
4. Remove: • Fuel sender(from the fuel tank)
5. Connect: • Fuel sender coupler
6. Push the start switch.
7. Check:
• Fuel level warning lightOut of specification  Replace the fuel
sender.
EAS2GC1346INSTALLING THE FUEL SENDER
1. Install: • Fuel sender gasket
• Fuel sender
TIP
• Do not damage the installation surfaces of the
fuel tank when installing the fuel sender.
• Always use a new fuel sender gasket.
• Install the fuel sender as shown in the illustra-
tion.
• When install the fuel sender, make sure that
the projection “a” faces the rear of the vehicle.
EAS2GC1347INSTALLING THE FUEL TANK
1. Install: • Fuel tank
2. Connect:
• Fuel hose
ECA
NOTICE
• Connect the fuel hose securely, and check that the orientation of the installed fuel
hose holder is correct.
• Take care not to kink or pinch the fuel
hose.
Fuel pump is atmosphere “A”
 Fuel level warning light is come on
Fuel pump is soaked in fuel “B”
 Fuel level warning light is goes off
a
b
4
1
2
6
5 3
Fuel sender bolts
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
New
T R..
a

9
ELECTRICAL SYSTEM
IGNITION SYSTEM.......................................................................................... 9-2
CIRCUIT DIAGRAM ................................................................................... 9-2
TROUBLESHOOTING ............................................................................... 9-4
ELECTRIC STARTING SYSTEM ..................................................................... 9-6
CIRCUIT DIAGRAM ................................................................................... 9-6
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................... 9-8
TROUBLESHOOTING ............................................................................. 9-10
CHARGING SYSTEM ..................................................................................... 9-12
CIRCUIT DIAGRAM ................................................................................. 9-12
TROUBLESHOOTING ............................................................................. 9-14
LIGHTING SYSTEM ....................................................................................... 9-16
CIRCUIT DIAGRAM ................................................................................. 9-16
TROUBLESHOOTING ............................................................................. 9-18
SIGNALING SYSTEM .................................................................................... 9-20
CIRCUIT DIAGRAM ................................................................................. 9-20
TROUBLESHOOTING ............................................................................. 9-22
COOLING SYSTEM ........................................................................................ 9-24
CIRCUIT DIAGRAM ................................................................................. 9-24
TROUBLESHOOTING ............................................................................. 9-26
FUEL INJECTION SYSTEM ........................................................................... 9-28
CIRCUIT DIAGRAM ................................................................................. 9-28
ECU SELF-DIAGNOSTIC FUNCTION ..................................................... 9-30
TROUBLESHOOTING METHOD ............................................................. 9-31
YAMAHA DIAGNOSTIC TOOL ................................................................ 9-32
TROUBLESHOOTING DETAILS ............................................................. 9-35
FUEL PUMP SYSTEM .................................................................................... 9-56
CIRCUIT DIAGRAM ................................................................................. 9-56
TROUBLESHOOTING ............................................................................. 9-58

ELECTRIC STARTING SYSTEM
9-8
EAS2GC1362STARTING CIRCUIT CUT-OFF SYSTEM OPERATION
If the meter light comes on, the starter motor can only operate if at least one of the following condi-
tions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these con-
ditions has been met. In this instance, the starting ci rcuit cut-off relay is open so current cannot reach
the starter motor. When at least one of the above conditions has been met the starting circuit cut-off
relay is closed and the engine can be started by pressing the start switch.

LIGHTING SYSTEM
9-16
LIGHTING SYSTEM
EAS2GC1366CIRCUIT DIAGRAM
ONOFF
ONOFF
BBB
BBB
RRR
RRR/L
Br Br Br
Br Br
(Gy)
(Gy)B/LGyWW W BGy
BR
WW W
BR
R,R/Y
G
R
Y/B
R,R/W
Br
RL/R
(B)R/YR/WBr/WL/G
Br/W,BrL/W
(B)
(B) Br BrL/Y
Y/R
G/YBrBB
BrBrL/YY/W
(B) (B)B BGG/Y
RR/L
RLg
W/B
(B)
BGyBr RW/BB/LLYP
G/WB/Y
R/BLgG/YW
Br/W
OL/RY/BB/OL/BSbY/R
L/Y P/L
Y/G
(Gy)R/L R/BR/LB/Y
R/WR/L
R/W,BrP/L
R/L R/L
(B)
(B) (B)
(L)
(L) (B)
BR/LLBR/L R/L R/L R/L R/L B/L B/L B/L B/L B/L B/L B/LLLLLBBBB
Br Br Br Br
B/LBr/W
B/LG/WLYB/L
B/LPLB/LY/GL
(B)
(B)B/OBBBSbW/B
Sb
SbG/B
L/G,L/WL/BBrG/BG/BB
BB
(B)
(B)L/BBBB
Br Br
Br BrBr
BB
LY
(B)
(B)
(B)
(B)
(B)
GB
ChDg YB
BRW
BrRBW
B/WRW
Ch DgYBBrR/WBW
R
O
OR/L
BB
B
B
BBBBBB
RRRRRR/L
BrBrBrBrBr
Br
Br
BrBrBrBrR/LR/LR/LR/LR/L
B
LLLP
PL
Y
Y
RR
Br
R/LR/L
R/L
P/L
P/L
R/L
R/L
R/LR/B
R/B
L/RL/Y
L/Y
Y/R
Y/R
G/Y
G/YG/Y
G/Y
B/Y
B/Y
R/LB/LB/L
B/LB/LB/LY/G
Y/GB/L
B/OL/BY/BW/B
W/B
G/B
L/B
W/BW/B
L/BL/BL/GL/W
L/W
L/R
Br/W
Br/W
R/W
R/W
R/Y
R/Y
G/BG/B
G/B
B/O
B/LB/LB/LB/LB/LB/LB/L
G/W
G/W
Br/W
Br/W
R/WR/WBr
O
O
RGy
LLLLBBBB
B
B
B
B
BB
B
B
RRWW
Y
Y
Dg
Dg
Ch
Ch
RW
BrBrBrBr
Br
B
W
Sb
SbSb
SbBr
Br
B
Br
Lg
Lg
R/L
R
R
RR
Gy
BB
WWWWWW
R
RRGGBB
B
Y/B
R
BB
Br
Br
Br
L/G
B/L
B/WB/W
OR
OR
BBB
B
BBBBB

LIGHTING SYSTEM
9-17
1. Joint connector
2. Joint connector
6. Headlight relay
7. Main relay
9. Battery
10.Frame ground
11.Starter relay
12.Main fuse
22.ECU (engine control unit)
30.Joint connector
42.Joint connector
43.Taillight
44.Headlight
47.Multi-function display
48.Frame ground
50.Negative battery lead

LIGHTING SYSTEM
9-18
EAS2GC1367TROUBLESHOOTING
Any of the following fail to light: headlight or meter light.
TIP
Before troubleshooting, remove the following part (s):
1. Seat
2. Side cover (left)
3. Air scoop (left/right)
4. Fuel tank1. Check the each bulbs condition. Refer to “CHECKING THE BULBS
AND BULB SOCKETS” on page 9-
67. NG

Replace the bulb (s).
OK 
2. Check the fuse. Refer to “CHECKING THE FUSES”
on page 9-68. NG

Replace the fuse(s).
OK 
3. Check the battery. Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69. NG

• Clean the battery terminals.
• Recharge or replace the battery.
OK 
4. Check the main relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG

Replace the main relay.
OK 
5. Check the headlight relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG

Replace the headlight relay.
OK 
6. Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-16. NG

Properly connect or repair the lighting sys-
tem’s wiring.
OK 
Replace the ECU, meter assembly, or
taillight.