2016 YAMAHA WR 450F Owners Manual

ELECTRICAL COMPONENTS
9-71
b. Connect a charger and ammeter to the bat-tery and start charging.
TIP
Set the charging voltage to 16–17 V. If the set-
ting is lower, charging will be insufficient. If too
high, the battery will be over-charged.
c. Make sure that the current is higher than the standard charging current written on the bat-
tery.
TIP
If the current is lower than the standard charg-
ing current written on the battery, set the charg-
ing voltage adjust dial at 20–24 V and monitor
the amperage for 3–5 minutes to check the bat-
tery.
d. Adjust the voltage so that the current is at
the standard charging level.
e. Set the time according to the charging time suitable for the open-circuit voltage.
f. If charging requires more than 5 hours, it is advisable to check the charging current after
a lapse of 5 hours. If there is any change in
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage af-
ter leaving the battery unused for more than
30 minutes.
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Charging method using a constant volt-
age charger
a. Measure the open-circuit voltage prior to charging.
TIP
Voltage should be measured 30 minutes after
the engine is stopped.
b. Connect a charger and ammeter to the bat-tery and start charging.
c. Make sure that the current is higher than the
standard charging current written on the bat-
tery.
TIP
If the current is lower than the standard charg-
ing current written on the battery, this type of
battery charger cannot charge the VRLA (Valve
Regulated Lead Acid) battery. A variable volt-
age charger is recommended.
d. Charge the battery until the battery’s charg-ing voltage is 15 V.
TIP
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage af-ter leaving the battery unused for more than
30 minutes.
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6. Install:
• Battery terminals
7. Connect:
• Battery leads(to the battery terminals)
ECA
NOTICE
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
8. Check:• Battery terminalsDirt  Clean with a wire brush.
Loose connection  Connect properly.
9. Lubricate: • Battery terminals
10.Install: • Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 5-
1.
• Standard charging current is reached
Battery is good.
• Standard charging current is not reached Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Recommended lubricantDielectric grease
2
1

ELECTRICAL COMPONENTS
9-72
EAS2GC1387CHECKING THE RELAYS
Check each switch for continuity with the pock-
et tester. If the continuity reading is incorrect,
replace the relay.
1. Disconnect the relay from the wire harness.
2. Connect the pocket tester ( 1) and bat-
tery (12 V) to the relay terminal as shown.
Check the relay operation.
Out of specification  Replace.
Starter relay
Main relay Starting circuit cut-off relay
Headlight relay
Radiator fan motor relay
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
1. Positive battery terminal
2. Negative ba ttery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
1. Positive battery terminal
2. Negative ba ttery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
21
3
4
R/WBr/WR/YL/G
1
2 3
4
L/R BrR
R,R/W
1. Positive ba ttery terminal
2. Negative ba ttery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
1. Positive ba ttery terminal
2. Negative ba ttery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” to “4”)
1. Positive ba ttery terminal
2. Negative ba ttery terminal
3. Positive tester probe
4. Negative tester probe
1
2 3
4
G/B L/B
L/G,L/W
1
2 3
4
R,R/Y
G R
1
2 3
4
P/L R/L
R/W
Br,R/W

ELECTRICAL COMPONENTS
9-73
EAS2GC1388CHECKING THE DIODE
1. Check:•DiodeOut of specification  Replace.
TIP
The pocket tester and the analog pocket tester
readings are shown in the following table.
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a. Disconnect the diode from the wire harness.
b. Connect the pocket tester (  1) to the di-
ode coupler as shown.
c. Check the diode for continuity.
d. Check the diode for no continuity.
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EAS2GC1389CHECKING THE IGNITION SPARK GAP
1. Check: • Ignition spark gapOut of specification  Perform the ignition
system troubleshooting, starting with step 4.
Refer to “TROUBLESHOOTING” on page 9-
4.
TIP
If the ignition spark gap is within specification,
the ignition system circui t is operating normally.
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a. Remove the spark plug cap from the spark
plug.
b. Connect the ignition checker “1” as shown.
c. Push the engine stop switch.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the start switch and gradually increase the spark gap until a
misfire occurs.
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EAS2GC1390CHECKING THE SPARK PLUG CAP
1. Remove:• Spark plug cap
(from the spark plug lead)
2. Check: • Spark plug cap resistance
Out of specification  Replace.
Result
Continuity
(between “3” to “4”)
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
No continuity Tester positive lead  Sky blue
“1”
Tester negative lead  Green/
Black “2”
Continuity Tester positive lead  Green/
Black “2”
Tester negative lead  Sky blue
“1”
No continuity Tester positive lead  Red “3”
Tester negative lead  Red/Blue
“4”
Continuity Tester positive lead  Red/Blue
“4”
Tester negative lead  Red “3”
2
1
4
3
R
Sb
G/B R/L
Minimum ignition spark gap 6.0 mm (0.24 in)
Ignition checker 90890-06754
Oppama pet–4000 spark checker YM-34487
2. Spark plug cap
Resistance 7.50–12.50 k 

ELECTRICAL COMPONENTS
9-74
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a. Connect the pocket tester ( 1k) to the
spark plug cap.
b. Measure the spark plug cap resistance.
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EAS2GC1391CHECKING THE IGNITION COIL
1. Disconnect: • Ignition coil terminal(from the sub wire harness)
• Spark plug cap (from the ignition coil)
2. Check:
• Primary coil resistanceOut of specification  Replace.
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a. Connect the pocket tester (  1) to the igni-
tion coil. b. Measure the primary coil resistance.
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3. Check:
• Secondary coil resistanceOut of specification  Replace.
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a. Connect the pocket tester (  1k) to the ig-
nition coil.
b. Measure the secondary coil resistance.
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EAS2GC1392CHECKING THE CRANKSHAFT POSITION
SENSOR
1. Disconnect: • Crankshaft position sensor coupler(from the wire harness)
2. Check:
• Crankshaft position sensor resistanceOut of specification  Replace.
Pocket tester
90890-03112
Analog pocket tester YU-03112-C
Primary coil resistance 2.16–2.64 
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe 
Ignition coil terminal 1 “1”
• Negative tester probe 
Ignition coil terminal 2 “2”
Secondary coil resistance 8.64–12.96 k 
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe  Ignition coil terminal 1 “1”
• Negative tester probe 
Spark plug lead “2”

ELECTRICAL COMPONENTS
9-75
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a. Connect the pocket tester ( 100) to the
crankshaft position sensor coupler.
b. Measure the crankshaft position sensor re- sistance.
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EAS2GC1393CHECKING THE LEAN ANGLE SENSOR
1. Remove:• Lean angle sensor
(from the bracket)
2. Check: • Lean angle sensor output voltage
Out of specification  Replace.
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a. Connect the lean angle sensor coupler to
the wire harness.
b. Connect the pocket tester (DC 20 V) to the
lean angle sensor coupler as shown. c. Incline the lean angle sensor.
d. Measure the lean angle sensor output volt-
age.
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EAS2GC1394CHECKING THE STARTER MOTOR OPERA-
TION
1. Check:• Starter motor operation
Does not operate  Perform the electric
starting system troubleshooting, starting
with step 4.
Refer to “ELECTRIC STARTING SYSTEM”
on page 9-6.
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a. Connect the positive battery terminal “1” and starter motor lead “2” with a jumper lead “3”.
EWA
WARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
• This check is likely to produce sparks, therefore, make sure no flammable gas or
fluid is in the vicinity.
Crankshaft position sensor resis-
tance
228–342 
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe 
Gray “1”
• Negative tester probe 
Black “2”
Lean angle sensor output voltageOperating angle45 °
Output voltage up to operating
angle 3.7–4.4 V
Output voltage over operating an-
gle 0.4–1.4 V
12
Gy B
Pocket tester90890-03112
Analog pocket tester YU-03112-C
Test harness– lean angle sensor
(6P) 90890-03209
Test harness– lean angle sensor
(6P) YU-03209
• Positive tester probe  Yellow/Green “1”
• Negative tester probe 
Black/Blue “2”
2
1
Ã45
Ã
45

ELECTRICAL COMPONENTS
9-76
b. Check the starter motor operation.
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EAS28150CHECKING THE STATOR COIL
1. Disconnect:• Stator coil coupler(from the wire harness)
2. Check:
• Stator coil resistanceOut of specification  Replace the stator
coil.
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a. Connect the pocket tester (  1) to the sta-
tor coil coupler as shown. b. Measure the stator coil resistance.
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EAS2GC1395CHECKING THE RECTIFIER/REGULATOR
1. Check:
• Charging voltageOut of specification  Replace the rectifier/
regulator.
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a. Set the digital tachometer to the ignition coil.
b. Connect the pocket tester (DC 20 V) to the rectifier/regulator coupler as shown.
c. Start the engine and let it run at approxi- mately 5000 r/min.
d. Measure the charging voltage.
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Stator coil resistance 0.528–0.792  (W–W)
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe 
White “1”
• Negative tester probe 
White “2”
• Positive tester probe  White “1”
• Negative tester probe 
White “3”
• Positive tester probe  White “2”
• Negative tester probe 
White “3”
No load regulated voltage 14.1–14.9 V
Digital tachometer 90890-06760
Digital tachometer YU-39951-B
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe  Red “1”
• Negative tester probe 
Black “2”
123
12

ELECTRICAL COMPONENTS
9-77
EAS2GC1396CHECKING THE SPEED SENSOR
1. Check:• Speed sensor output voltageOut of specification  Replace.
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a. Connect the test harness-speed sensor (3P)
to the speed sensor coupler and wire har-
ness.
b. Connect the pocket tester (DC20V) to the test harness-speed sensor (3P).
c. Push the start switch.
d. Elevate the front wheel and slowly turn it.
e. Measure the voltage (DC 5 V) of white and black/white. With the front wheel slowly ro-
tating, voltage alternates between 0 V and 5
V.
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EAS2GC1397CHECKING THE FUEL SENDER
1. Drain the gasoline.
2. Disconnect:• Fuel sender coupler
(from the fuel sender)
3. Remove:
• Fuel sender(from the fuel tank) 4. Check:
• Fuel sender resistanceOut of specification  Replace the fuel
sender.
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a. Connect the pocket tester (  1k) to the
fuel sender as shown.
b. Measure the resistance of the fuel sender.
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EAS2GC1398CHECKING THE RESISTER
1. Disconnect: • Resister coupler(from the wire harness)
2. Check: • Resister resistanceOut of specification  Replace the resister.
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a. Connect the pocket tester (  10) to the re-
sister as shown.
Output voltage reading cycle
0.6V to 4.8V to 0.6V to 4.8V
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
Test harness– speed sensor 5TJ
(3P) 90890-03228
Test harness– speed sensor 5TJ
(3P) YU-03228
• Positive tester probe  White “1”
• Negative tester probe 
Black “2”
BRW
21
Fuel sender resistance
1.35–1.90 k  at 25°C (77°F)
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe  Green “1”
• Negative tester probe 
Black “2”
Resister resistance64.6–71.4 
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
1
2

ELECTRICAL COMPONENTS
9-78
b. Measure the resistance of the resister.
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EAS2GC1399CHECKING THE RADIATOR FAN MOTOR
1. Check:• Radiator fan motor
Faulty/rough movement  Replace.
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a. Disconnect the radiator fan motor coupler
from the wire harness.
b. Connect the battery (DC 12 V) as shown.
c. Measure the radiator fan motor movement.
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EAS2GC1400CHECKING THE COOLANT TEMPERATURE
SENSOR
1. Remove: • Coolant temperature sensor
EWA
WARNING
• Handle the coolant temperature sensor with special care.
• Never subject the coolant temperature sensor to strong shocks. If the coolant
temperature sensor is dropped, replace it. 2. Check:
• Coolant temperature sensor resistanceOut of specification  Replace.
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a. Connect the pocket tester (  1k/100) to
the coolant temperature sensor.
b. Immerse the coolant temperature sensor in a container filled with coolant.
TIP
Make sure the coolant temperature sensor ter-
minals do not get wet.
c. Place a thermometer in the coolant.
d. Slowly heat the coolant, and then let it cool to the specified temperature indicated in the
table.
e. Check the coolant temperature sensor for continuity at the temperatures indicated in
the table.
• Positive tester probe 
Black “1”
• Negative tester probe 
Black “2”
• Positive battery terminal 
Blue “1”
• Negative battery terminal 
Black “2”
1
2
12
12V
LB
Coolant temperature sensor re-
sistance 2512–2777  at 20 °C (2512–
2777  at 68 °F)
210–220  at 100 °C (210–220 
at 212 °F)
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe  Green/White “1”
• Negative tester probe 
Black/Blue “2”
12
G/W B/L
B/LG/W