2016 YAMAHA WR 450F oil

PERIODIC MAINTENANCE
3-4
EAS2GC1078MAINTENANCE INTERVALS FOR COMPETITION USE
TIP
• The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the re-
quired maintenance and lubrication intervals. If you ar e a doubt as to what intervals to follow in
maintaining and lubricating your ma chine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the machine performance. The service life of
the parts varies substantially according to the en vironment in which the machine runs (e.g., rain,
dirt, etc.). Therefore, earlier inspection is required by reference to the list below.
ITEM After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks
ENGINE OIL Replace
VALVES Check the valve
clearances The engine must be cold.
Inspect Check the valve seats and
valve stems for wear.
Replace
VALVE SPRINGS Inspect Check the free length and the
tilt.
Replace
VALVE LIFTERS Inspect Check for scratches and wear.
Replace
CAMSHAFTS Inspect the camshaft surface.
Inspect Inspect the decompression
system.
Replace
CAMSHAFT
SPROCKETS Inspect Check for wear on the teeth
and for damage.
Replace
PISTON Inspect crack.
Inspect Inspect carbon deposits and
eliminate them.
Clean
Replace It is recommended that the pis-
ton pin and ring are also re-
placed at the same time.
PISTON RING
Inspect Check ring end gap.
Replace

PERIODIC MAINTENANCE
3-6
COOLING SYSTEMCheck coolant lev-
el and leakage
Check radiator cap
operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS
AND BOLTS
Retighten Refer to “STARTING AND
BREAK-IN” on page 1-28.
AIR FILTER
Clean and lubri-
cate Use Yamaha foam air filter oil
or other quality foam air filter
oil.
Replace
OIL FILTER
Replace
ENGINE GUARD Replace Breakage
FRAME Clean and inspect
FUEL TANK, FUEL
PUMP
Clean and inspect
FUEL HOSE Inspect
Replace Every four years
ITEM
After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks

PERIODIC MAINTENANCE
3-7
BRAKESAdjust lever posi-
tion and pedal
height
Lubricate pivot
point
Check brake disc
surface
Check fluid level
and leakage
Retighten brake
disc bolts, caliper
bolts, master cylin-
der bolts and union
bolts
Replace pads
Replace brake flu-
id Every one year
FRONT FORKS Inspect and adjust
Replace oil Yamaha Suspension Oil S1
Replace oil seal
FRONT FORK OIL
SEAL AND DUST
SEAL Clean and lube Lithium-soap-based grease
PROTECTOR
GUIDE
Replace
REAR SHOCK AB-
SORBER (After
rain
ride)
Inspect and adjust
Lube Molybdenum disulfide grease
Retighten
DRIVE CHAIN
GUARD AND ROLL-
ERS
Inspect
DRIVE CHAIN
STOPPER Inspect ITEM
After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks

PERIODIC MAINTENANCE
3-8
SWINGARMInspect, lube and
retighten Molybdenum disulfide grease
RELAY ARM, CON-
NECTING ROD Inspect, lube and
retighten Molybdenum disulfide grease
SIDESTAND Lubricate Lithium-soap-based grease
STEERING HEAD Inspect free play
and retighten
Clean and lube Lithium-soap-based grease
Replace bearing
TIRE, WHEELS
Inspect air pres-
sure, wheel run-
out, tire wear and
spoke looseness
Retighten sprocket
bolt
Inspect bearings
Replace bearings
Lubricate Lithium-soap-based grease
THROTTLE, CON-
TROL CABLE
Check routing and
connection
Lubricate Yamaha cable lube or SAE
10W-30 motor oil
ITEM
After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks

PRE-OPERATION INSPECTION AND MAINTENANCE
3-9
EAS2GC1079
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAS2GC1080GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
Coolant Check that coolant is filled up to the radiator cap.
Check the cooling system for leakage. 3-10 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage. 1-28
Engine oil Check that the oil level is correct. Check the crank-
case and oil line for leakage. 3-16 – 18
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly. 3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary. 3-13 – 14
Brakes Check the play of front brake and effect of front and
rear brake. 3-25 – 31
Drive chain Check drive chain slack and alignment. Check that
the drive chain is lubricated properly. 3-31
5-69 – 70
Wheels Check for excessive wear and tire pressure. Check
for loose spokes and have no excessive play. 3-36 – 37
Steering Check that the handlebar can be turned smoothly and
have no excessive play. 3-37 – 38
Front forks and rear
shock absorber Check that they operate smoothly and there is no oil
leakage.
3-31 – 36
Cables (wires) Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and
has no cracks. 3-15 – 16
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is
not loose. 5-10 – 11
Lubrication Check for smooth operation. Lubricate if necessary. 3-14
3-38 – 39
Bolts and nuts Check the chassis and engine for loose bolts and
nuts. 1-32 – 33
Lead connectors Check that the AC magneto, ECU and ignition coil are
connected tightly. 1-9 – 12
Settings Is the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?
4-1 – 8

ENGINE
3-14
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1090LUBRICATING THE THROTTLE CABLE
1. Remove:• Cover (throttle cable cap) “1”
• Cover (grip cap) “2”
• Throttle grip cap “3”
2. Lubricate: • Throttle cable end “a”
3. Install: • Throttle grip cap
• Screw (throttle grip cap) 4. Install:
• Cover (grip cap)
• Cover (throttle cable cap)
EWA
WARNING
Check that the throttle grip moves smooth-
ly. If this does not move smoothly, correct
the installed positions.
EAS2GC1091CLEANING THE AIR FILTER ELEMENT
1. Remove:• Fuel tank cap cover “1”Refer to “FUEL TANK CAP” on page 1-20.
• Air filter case cover “2”
TIP
Loosen the quick fastener screw “3” and re-
move the air filter case cover.
2. Remove:
• Air filter mounting bolt “1”
• Air filter element “2”
• Air filter guide “3” (from the air filter element)
3. Wash: • Air filter element
EWA
WARNING
Do not use gasoline or organic (acid/alka-
line) volatile oil for washing.
TIP
After washing the element with air filter cleaner
or kerosene, squeeze and dry it completely.
ECA
Recommended lubricantLithium-soap-based grease
Screw (throttle grip cap) 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
1
2
b
a
T R..
1
2
3
3
3
13
2

ENGINE
3-15
NOTICE
Do not twist the element when squeezing
the element.
4. Check:• Air filter element
Damage  Replace.
5. Yamaha foam air filter oil or other quality foam air filter oil.
TIP
Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:• Air filter guide “1” (to the air filter element)
• Air filter element “2”
• Air filter mounting bolt “3”
7. Install: • Air filter case cover “1”
TIP
Align the air filter case cover groove “a” with the
air filter case edge “b”. 8. Install:
• Fuel tank cap cover
EAS2GC1092CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body jointRefer to “CHECKING THE THROTTLE
BODY JOINT” on page 8-10.
EAS2GC1093CHECKING THE BREATHER HOSES
1. Check:• Breather hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
ECA
NOTICE
Make sure the cylinder head breather hose
is routed correctly.
EAS2GC1094CHECKING THE EXHAUST SYSTEM
1. Remove:
• Exhaust pipe protector
2. Check: • Exhaust pipe 1
• Exhaust pipe 2
• SilencerCrack/damage  Replace.
Refer to “ENGINE REMOVAL” on page 6-1.
• Exhaust gas Leaks  Replace the gasket.
Refer to “ENGINE REMOVAL” on page 6-1.
Oil application quantify
50 g
Air filter mounting bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
T R..
31
2
a
b
1
1

ENGINE
3-16
3. Check:• Tightening torques
4. Install: • Exhaust pipe protector
EAS2GC1095CHECKING THE FUEL LINE
1. Remove:• Seat
• Side cover (left/right)
• Air scoop (left/right)Refer to “GENERAL CHASSIS” on page 5-
1.
• Fuel tank Refer to “FUEL TANK” on page 8-1.
2. Check:
• Fuel hose “1”Crack/damage  Replace.
Loose connection  Connect properly. 3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 8-1.
• Air scoop (left/right)
• Seat
• Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-
1.
EAS2GC1096CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle upright on a level surface.
2. Start the engine, warm this up for 2–3 min- utes, and then stop the engine and wait
about 1 minute.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
3. Check:
• Oil levelMake sure that the engine oil level is above
the minimum level mark “a” shown for the oil
level check window “1”, and that the engine
oil does not come out by removing the oil
check bolt “2”.
The minimum level mark “a” or below  Add
the engine oil until its level exceeds the min-
imum level mark “a”.
Engine oil coming out of the oil check bolt 
Drain it until its last drop is out.
ECA33DD018
Exhaust pipe bolt 1 and nut “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe 1 and exhaust pipe
2 bolt “2” 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Exhaust pipe 2 and silencer bolt
“3” 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer and silencer bracket bolt
“4” 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe protector screw 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
T R..
2
1
4
3
T R..
1
12
a