2016 YAMAHA WR 450F engine oil

CLUTCH
6-46
EAS2GC1276CHECKING THE PRIMARY DRIVEN GEAR
1. Check:• Primary driven gearDamage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Re-
place the primary drive and primary driven
gears as a set.
EAS2GC1277INSTALLING THE OIL SEAL
1. Install: • Oil seal “1”
• Washer “2”
• Circlip “3”
TIP
• Apply the lithium-soap-based grease on the
oil seal lip.
• Install the oil seal in parallel with its manufac-
ture's marks or numbers facing inward.
EAS2GC1278INSTALLING THE RIGHT CRANKCASE
COVER
1. Install: • Dowel pin “1”
• O-rings “2”
• Collar “3”
• Gasket “4”
TIP
Apply the lithium-soap-based grease on the O-
ring.
2. Install:
• Right crankcase cover “1” • Right crankcase cover bolt “2”
TIP
• Apply the engine oil on the impeller shaft end.
• When installing the crankcase cover onto the
crankcase, make sure that the impeller shaft
end “3” aligns with the balancer end slot “4”.
• Tighten the right crankcase cover bolts in
stages and in a crisscross pattern.
EAS2GC1279INSTALLING THE CLUTCH
1. Install:
• Push lever shaft “1”
TIP
• Apply the lithium-soap-based grease on the oil seal lip.
• Before installation, apply the engine oil to the
push lever shaft sliding surface.
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3
2
1
LS
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1
1
4
2
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3
LS
Right crankcase cover bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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1 2
1

CLUTCH
6-47
2. Install:• Primary driven gear “1”
• Thrust washer “2”
• Clutch boss “3”
TIP
Apply the engine oil on the primary driven gear
inner circumference.
3. Install:• Conical washer “1”
• Clutch boss nut “2”
ECA1DX1020
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is
fastened together.
TIP
• Install the conical washer with its convex sur-face “a” outward.
• Apply engine oil to the threads and contact surface of the clutch boss nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Use the clutch holding tool “3” to hold the
clutch boss. 4. Install:
• Friction plate 1 “1”
• Clutch plate 2 “2”
• Cushion spring “3”
• Friction plate 2 “4”
• Clutch plate 1 “5”
TIP
• Install the clutch plates and friction plates al-
ternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• From the clutch boss side, install the friction
plates in order: friction plate 1  2, friction
plate 2 (identification color: purple)  5, and
friction plate 1  1.
• From the clutch boss side, the clutch plate in order: clutch plate 2 (thickness: 1.6 mm)  3,
and clutch plate 1 (thickness: 2.0 mm)  4.
• Apply the engine oil on the friction plates and
clutch plates.
Clutch boss nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
Universal clutch holder 90890-04086
Universal clutch holder YM-91042
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a. Identification color
a2
3
21
1
314
225
1 4
5
a
4 53
4
2
1

CLUTCH
6-48
5. Install:• Bearing “1”
• Washer “2”
• Circlip “3” To push rod 1 “4”.
TIP
Apply the engine oil on the bearing and washer.
6. Install:• Push rod 2 “1”
•Ball “2”
• Push rod 1 “3”
TIP
Apply the engine oil on the push rod 1, 2 and
ball.
7. Install:
• Pressure plate “1” 8. Install:
• Clutch spring
• Clutch spring bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
9. Install:• O-ring “1”
TIP
Apply the lithium-soap-based grease to the O-
ring.
10.Install:• Clutch cover “1”
• Clutch cover bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
NewClutch spring bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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KICKSTATER
6-52
3. Install:• Spring guide “1”
TIP
Slide the spring guide into the kick shaft, make
sure the groove “a” in the spring guide fits on
the stopper of the torsion spring.
4. Install:• Kick shaft assembly “1”
TIP
• Before installation, apply molybdenum disul-fide grease to the contacting surfaces of the
kick shaft ratchet wheel guide “2” and the kick
shaft stopper “a”.
• Apply the engine oil on the kick shaft.
• Slide the kick shaft assembly into the crank-
case and make sure the kick shaft stopper “a”
fits into the kick shaft ratchet wheel guide. 5. Install:
• Torsion spring “1”
TIP
Turn the torsion spring clockwise and hook into
the proper hole “a” in the crankcase.
EAS2GC1286INSTALLING THE KICK IDLE GEAR
1. Install:• Kick idle gear “1”
• Washer “2”
• Circlip “3”
TIP
• Apply the engine oil on the kick idle gear inner circumference.
• Install the kick idle gear with its depressed
side “a” toward you.
1
2
a
b
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SHIFT SHAFT
6-55
EAS2GC1293INSTALLING THE STOPPER LEVER
1. Install:• Torsion spring “1”
• Collar “2”
• Stopper lever “3”
• Bolt (stopper lever) “4”
EAS2GC1294INSTALLING THE SEGMENT
1. Install:• Segment “1”
• Segment bolt
TIP
• Align the notch “a” on the segment with the pin “b” on the shift cam.
• With the stopper lever pushed down, install
the segment.
ECA
NOTICE
If the segment gets an impact, the stopper
lever may be damaged. Take care not to
give an impact to it when tightening the bolt.
EAS2GC1295INSTALLING THE SHIFT GUIDE AND SHIFT
LEVER ASSEMBLY
1. Install: • Spring “1”
• Pawl pin “2”
•Pawl “3”(to the shift lever “4”)
TIP
Apply the engine oil on the spring, pawl pin and
pawl.
2. Install:
• Shift lever assembly “1”(to the shift guide “2”)
3. Install: • Shift lever assembly “1”
• Shift guide “2”
TIP
• The shift lever assembly is installed at the
same time as the shift guide.
• Apply the engine oil on the segment bolt shaft.
Bolt (stopper lever)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Segment bolt 30 Nm (3.0 m·kgf, 22 ft·lbf)
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2
1
3
4
LT
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2
1
2

SHIFT SHAFT
6-56
4. Tighten:• Shift guide bolt “1”
EAS2GC1296INSTALLING THE SHIFT SHAFT
1. Install:• Roller “1”
• Shift haft spring “2” (to shift shaft)
• Collar “3” (to shift shaft)
• Shift shaft “4”
TIP
Apply the engine oil on the roller, collar and
shift shaft.
2. Install:• Oil seal
EAS2GC1297INSTALLING THE SHIFT PEDAL
1. Install:• Shift pedal “1”
• Shift pedal bolt “2”
TIP
Align the punch mark “a” on the shift shaft with
the punch mark “b” in the shift pedal. Shift guide bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Shift pedal bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
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1
1
LT
E
E
1
2 3
4
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a
12 b

OIL PUMP AND BALANCER GEAR
6-60
3. Check:• Oil pump operationRough movement  Repeat steps (1) and
(2) or replace the defective part(s).
EAS2GC1303ASSEMBLING THE OIL PUMP
1. Install: • Oil pump drive shaft “1”
• Inner rotor “2”
• Dowel pin “3”
TIP
• Apply the engine oil on the oil pump drive shaft and inner rotor.
• Fit the dowel pin into the groove in the inner
rotor.
2. Install: • Outer rotor “1”
TIP
Apply the engine oil on the outer rotor.
3. Install:• Oil pump cover “1”
• Oil pump cover screw “2”
Inner-rotor-to-outer-rotor-tip
clearance
0.000–0.150 mm (0.0000–0.0059
in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-
outer-rotor clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.17 mm (0.0067 in)
1. Inner rotor
2. Outer rotor
3. Oil pump housing
b
a
1
2
3
c
Oil pump cover screw
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
21
3
1
E
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2
1

OIL PUMP AND BALANCER GEAR
6-61
EAS2GC1304INSTALLING THE OIL PUMP AND BALANC-
ER GEAR
1. Install:• Oil pump assembly “1”
• Oil pump assembly bolt “2”
ECA1DX1023
NOTICE
After tightening the bolts, make sure that
the oil pump turns smoothly.
2. Install:• Balancer weight gear “1”
TIP
Install the balancer weight gear and balancer
shaft with their lower sp lines “a” aligning with
each other.
3. Install:
• Balancer drive gear “1”
TIP
• Align the punched mark “a” on the balancer drive gear with the punched mark “b” on the
balancer weight gear.
• Install the balancer drive gear and crankshaft with the lower splines “c” aligning with each
other. 4. Install:
• Lock washer “1”
• Balancer weight gear nut “2”
• Primary drive gear “3”
• Conical washer “4”
• Primary drive gear nut “5”
• Straight key “6”
•Balancer “7”
• Lock washer “8”
• Balancer nut “9”
TIP
• Apply engine oil to the contact surface and threaded portion of the primary drive gear nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Place an aluminum plate “a” between the teeth of the balancer drive gear “10” and bal-
ancer weight gear “11”.
• Install the conical wash er with its convex sur-
face “b” outward.
Oil pump assembly bolt
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
LOCTITE®
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1
2
LT
Balancer weight gear nut50 Nm (5.0 m·kgf, 36 ft·lbf)
Primary drive gear nut 100 Nm (10 m·kgf, 72 ft·lbf)
Balancer nut 45 Nm (4.5 m·kgf, 33 ft·lbf)
ba
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