2016 YAMAHA WR 450F check oil

FRONT FORK
5-45
4. Measure:• Oil level (left and right) “a”
Out of specification  Regulate.
5. Tighten: • Locknut “1”
TIP
Fully finger tighten the locknut onto the damper
assembly. 6. Loosen:
• Compression damping force adjuster “1”
TIP
• Before loosening the damping force adjuster, record the setting position.
• Unless the damping force adjuster is fully loosened, correct damping characteristic can-
not be obtained after installation.
7. Install: • Base valve “1”(to the damper assembly “2”)
TIP
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releas-
ing the damper rod pressure.
8. Check:• Damper assembly
Not fully stretched  Repeat the steps 1 to
7.
Standard oil level
145–148 mm (5.71–5.83 in)
From top of fully stretched
damper assembly.
1
a1
1
2

FRONT FORK
5-46
9. Tighten:• Base valve “1”
TIP
Hold the damper assembly with the cap bolt
ring wrench “2” and use the cap bolt wrench “3”
to tighten the base valve.
10.After filling, pump the damper assembly “1” slowly up and down more than 10 times to
distribute the fork oil.
11.While protecting the damper assembly “1” with a cloth and compressing fully, allow ex-
cessive oil to overflow on the base valve
side.
ECA
NOTICE
Take care not to damage the damper assem-
bly. 12.Allow the overflowing oil to escape at the
hole “a” in the damper assembly.
TIP
The overflow measures about 10 cm3 (0.34 US
oz, 0.35 lmp.oz).
13.Check:
• Damper assembly smooth movementTightness/binding/rough spots  Repeat
the steps 1 to 12.
14.Install: • Dust seal “1”
• Oil seal clip “2”
• Oil seals “3”
• Washer “4”
• Outer tube bushing “5” (to the inner tube “6”)
ECA
NOTICE
Make sure that the numbered side of the oil
seal faces bottom side.
Base valve
28 Nm (2.8 m·kgf, 20 ft·lbf)
Cap bolt wrench 90890-01500
Cap bolt wrench YM-01500
Cap bolt ring wrench 90890-01501
Cap bolt ring wrench YM-01501
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1
2 3
1
1
a
New
New
New

FRONT FORK
5-48
19.Install:• Oil seal clip “1”
TIP
Fit the oil seal clip correctly in the groove in the
outer tube.
20.Install:
• Dust seal “1”
TIP
Apply lithium-soap-based grease on the inner
tube.
21.Check:• Inner tube smooth movementTightness/binding/rough spots  Repeat
the steps 14 to 20. 22.Measure:
• Distance “a”
Out of specification  Turn into the locknut.
23.Install: • Collar “1”
• Fork spring “2”(to the damper assembly “3”)
TIP
Install the collar with its larger dia. end “a” fac-
ing the fork spring.
New
Distance “a”16 mm (0.63 in) or more
Between the damper assembly
“1” bottom and locknut “2” bot-
tom.
1 2a
12
3 a

REAR SHOCK ABSORBER ASSEMBLY
5-62
2. Remove:• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1212CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
•Spring
Damage/wear  Replace. • Spring guide
Damage/wear  Replace.
• Bearing
Damage/wear  Replace.
•Bolts Bends/damage/wear  Replace.
EAS2GC1213CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
2. Check: • Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check: • Oil sealsDamage/pitting  Replace.
EAS2GC1214INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install: • Bearing “1”
• Washer “2”
• Oil seals “3” (to relay arm “4”)
1
Recommended lubricantMolybdenum disulfide grease
Installed depth “a” 0 mm (0 in)
New
3
3
43
2 2
2 2
a
1 1 1

SWINGARM
5-66
EAS2GC1217REMOVING THE SWINGARM
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. Measure:• Swingarm side play
• Swingarm vertical movement
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a. Measure the tightening torque of the pivot shaft nut.
b. Measure the swingarm side play “a” by mov- ing the swingarm from side to side.
c. If the swingarm side play is out of specifica- tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b” by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
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EAS2GC1218REMOVING THE BEARING
1. Remove:• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1219CHECKING THE SWINGARM
1. Check:• Swingarm
Bends/cracks/damage  Replace.
2. Check: • Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check: • Oil seals
Damage  Replace.
• Bearing
• Spacers Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set.
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial) 1.0 mm (0.04 in)
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CLUTCH......................................................................................................... 6-41
REMOVING THE CLUTCH ...................................................................... 6-44
CHECKING THE FRICTION PLATES...................................................... 6-44
CHECKING THE CLUTCH PLATES ........................................................ 6-44
CHECKING THE CLUTCH SPRINGS...................................................... 6-44
CHECKING THE CLUTCH HOUSING ..................................................... 6-45
CHECKING THE CLUTCH BOSS ............................................................ 6-45
CHECKING THE PRESSURE PLATE ..................................................... 6-45
CHECKING THE PUSH LEVER SHAFT .................................................. 6-45
CHECKING THE CLUTCH PUSH RODS ................................................ 6-45
CHECKING THE PRIMARY DRIVE GEAR .............................................. 6-45
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 6-46
INSTALLING THE OIL SEAL ................................................................... 6-46
INSTALLING THE RIGHT CRANKCASE COVER ................................... 6-46
INSTALLING THE CLUTCH ..................................................................... 6-46
INSTALLING THE KICKSTAR TER LEVER ............................................. 6-49
KICKSTATER ................................................................................................. 6-50
REMOVING THE KICK SHA FT ASSEMBLY ........................................... 6-51
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 6-51
CHECKING THE KICK GEAR, KICK IDLE GEAR AND RATCHET
WHEEL .................................................................................................... 6-51
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 6-51
INSTALLING THE KICK IDLE GEAR ....................................................... 6-52
SHIFT SHAFT ................................................................................................. 6-53
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-54
REMOVING THE SEGMENT ................................................................... 6-54
CHECKING THE SHIFT SHAFT .............................................................. 6-54
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 6-54
CHECKING THE STOPPER LEVER ....................................................... 6-54
INSTALLING THE STOPPE R LEVER ............................. ........................ 6-55
INSTALLING THE SEGMENT.................................................................. 6-55
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 6-55
INSTALLING THE SHIFT SHAFT ............................................................ 6-56
INSTALLING THE SHIFT PEDAL ............................................................ 6-56
OIL PUMP AND BALANCER GEAR ............................................................. 6-57
REMOVING THE BALANCER ................................................................. 6-59
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT DRIVE GEAR, AND BALANCER WEIGHT GEAR .................................. 6-59
CHECKING THE BALANCER .................................................................. 6-59
CHECKING THE OIL PUMP .................................................................... 6-59
ASSEMBLING THE OIL PUMP ................................................................ 6-60
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 6-61

GENERATOR AND STARTER CLUTCH....................................................... 6-63
REMOVING THE GENERATOR .............................................................. 6-65
CHECKING THE STARTER CLUTCH ..................................................... 6-65
INSTALLING THE STARTER CLUTCH ................................................... 6-66
INSTALLING THE GENERATOR............................................................. 6-67
CRANKCASE ................................................................................................. 6-69
DISASSEMBLING THE CRANKC ASE..................................................... 6-72
REMOVING THE CRANKCASE BEARING ............................................. 6-72
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL
STRAINER .............................................................................................. 6-72
CHECKING THE CRANKCASE ............................................................... 6-72
INSTALLING THE OIL SEAL ................................................................... 6-73
ASSEMBLING THE CRANKCASE........................................................... 6-73
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT ............................... 6-74
REMOVING THE BALANCER SHAFT..................................................... 6-75
REMOVING THE CRANKSHAFT ASSEMBLY ........................................ 6-75
CHECKING THE CRANKSHA FT ASSEMBLY......................................... 6-75
INSTALLING THE CRANKSHA FT ASSEMBLY....................................... 6-76
TRANSMISSION ............................................................................................. 6-77
REMOVING THE TRANSMISSION ......................................................... 6-78
CHECKING THE SHIFT FORKS.............................................................. 6-78
CHECKING THE SHIFT DRUM ASSEMBLY ........................................... 6-79
CHECKING THE TRANSMISSION .......................................................... 6-79
INSTALLING THE TRANSMISSION ........................................................ 6-79

CAMSHAFT
6-16
EAS2GC1242CHECKING THE DECOMPRESSION SYS-
TEM
1. Check:• Decompression system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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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