2016 YAMAHA WR 450F engine oil

GENERATOR AND STARTER CLUTCH
6-63
EAS2GC1305
GENERATOR AND STARTER CLUTCH
Removing the generator
Order Job/Parts to remove Q’tyRemarks
Drain the engine oil. Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Seat and fuel tank Refer to “GENERAL CHASSIS” on page 5-1
and “FUEL TANK” on page 8-1.
Disconnect the AC magneto lead.
Clutch cable
Shift pedal Refer to “SHIFT SHAFT” on page 6-53.
1 Cover (Damper assembly) 1
2 Damper assembly 1
3 Left crankcase cover 1
4Gasket 1
5 Dowel pin 2
6 Starter idle gear 1
7 Bearing 1
8 Starter idle gear shaft 1
9 Generator rotor 1
10 Woodruff key 1
T R..
T R..
T R..
5
5 10
87
6
21
13 3
4
11 9
12
T R..
T R..
T R..LT
LT
T R..
T R..
14
LT
LT

GENERATOR AND STARTER CLUTCH
6-66
EAS2GC1308INSTALLING THE STARTER CLUTCH
1. Install:• Stator “1”
• Stator bolt “2”
• Crankshaft position sensor “3”
• Holder “4”
• Crankshaft position sensor bolt “5”
TIP
• Pass the stator coil lead between ribs “a”, and put it in part “b” so that there is no slack.
• Pass crankshaft sensor lead “c” over stator
coil lead “d”.
• Pass the crankshaft sensor lead outside of rib “a” and place the excess end next to boss “e”.
• Make sure that the end surface of holder “f” does not get caught on rib “a”.
• Place the stator coil lead and crankshaft sen-
sor lead inside the U-shaped space “g”of the
holder.
• Tighten the stator bolt using the T25 bit.
• Apply the sealant to the grommet of the AC
magneto lead. 2. Install
• Starter clutch drive gear “1”
TIP
Apply the engine oil on the starter clutch drive
gear inner circumference.
Stator bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LOCTITE®
Crankshaft position sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Yamaha bond No. 1215 90890-85505
(Three bond No.1215®)
T R..
T R..
g
d
c
ea
a
b
f
LT

GENERATOR AND STARTER CLUTCH
6-67
3. Install:• Starter clutch “1”To generator rotor “2”.
EAS2GC1309INSTALLING THE GENERATOR
1. Install:
• Woodruff key “1”
• Generator rotor “2”
TIP
• Clean the contact surfaces of the tapered por-tions of the crankshaft and generator rotor.
• When installing the woodruff key, make sure that its flat surface “a” is in parallel with the
crankshaft center line “b”.
• When installing the generator rotor, align the keyway “c” of the generator rotor with the
woodruff key.
2. Install: • Washer
• Generator rotor nut “1” 3. Install:
• Starter idle gear shaft “1”
• Bearing “2”
• Starter idle gear 2 “3”
TIP
Apply the engine oil on the starter idle gear
shaft, bearing and idle gear inner circumfer-
ence.
4. Install:
• Dowel pin
• Crankcase cover gasket
• Left crankcase cover “1”
• Lead holder “2”
• Crankcase cover bolt
• Neutral switch lead “3”
TIP
• Pass the AC magneto lead “4” under the left crankcase cover “a” as shown.
• Tighten the bolts in stage, using a crisscross
pattern.
Starter clutch bolt
16 Nm (1.6 m·kgf, 12 ft·lbf)
LOCTITE®
Generator rotor nut 65 Nm (6.5 m·kgf, 47 ft·lbf)
21
LT
T R..
2
C
1 1
1a
b
T R..
Crankcase cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
1
2 1
2
3
New
T R..

GENERATOR AND STARTER CLUTCH
6-68
5. Install:• Washer “1”
• Damper assembly “2”
• Washer “3”
TIP
Apply the engine oil to the shaft and washers.
6. Install:• Cover (damper assembly) “1”
• Bracket “2”
•Bolt “3”
TIP
Install the cover (damper assembly) with its
mark “a” facing upward. Bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
4
1 a
1
2
3
2
1
2
3
T R..
1a3
3
2

CRANKCASE
6-69
EAS2GC1310
CRANKCASE
Separating the crankcase
OrderPart name Q’tyRemarks
Engine Refer to “ENGINE REMOVAL” on page 6-1.
Piston Refer to “CYLINDER AND PISTON” on page
6-31.
Balancer Refer to “OIL PUMP AND BALANCER
GEAR” on page 6-57.
Kick shaft assembly Refer to “KICKSTATER” on page 6-50.
Segment Refer to “SHIFT SHAFT” on page 6-53.
Stator Refer to “GENERATOR AND STARTER
CLUTCH” on page 6-63.
1 Timing chain guide (exhaust side) 1
2 Timing chain guide stopper plate 1
3 Timing chain 1
4 Bolt [L = 45 mm (1.77 in)] 6
5 Bolt [L = 60 mm (2.36 in)] 4
6 Bolt [L = 75 mm (2.95 in)] 2
7 Right crankcase 1
8 Left crankcase 1
9 Dowel pin 2
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
3
1
5
2 6410
5
5
4
4 4 46
9 7
8
11
9
LT
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
LT

CRANKCASE
6-72
EAS2GC1311DISASSEMBLING THE CRANKCASE
1. Separate:• Right crankcase
• Left crankcase
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a. Remove the crankcase bolts.
TIP
Loosen each bolt 1/4 of a turn at a time and af-
ter all the bolts are loosened, remove them.
b. Remove the right crankcase “1”.
TIP
• Place the crankcase with its left side down-ward and split it by inserting a screwdriver tip
into the splitting slit “a” in the crankcase.
• Lift the right crankcase horizontally while light-
ly patting the crankcase splitting slit and the
engine mounting boss using a soft hammer,
and leave the crankshaft and the transmission
with the left crankcase.
ECA33DD041
NOTICE
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If the cases do not
separate, check for a remaining case bolt or
fitting. Do not force. c. Remove the dowel pins and O-ring.
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EAS2GC1312REMOVING THE CRANKCASE BEARING
1. Remove:
• Bearing “1”
TIP
• Remove the bearing from the crankcase by pressing its inner race.
• Do not use the removed bearing.
EAS2GC1313CHECKING THE TIMING CHAIN, TIMING
CHAIN GUIDE, OIL STRAINER
1. Check:• Timing chainStiffness  Replace the camshaft sprocket,
timing chain and crankshaft sprocket as a
set.
2. Check: • Timing chain guide
Damage/wear  Replace
EAS2GC1314CHECKING THE CRANKCASE
1. Wash:
• Crankcase
TIP
• Wash the crankcase in a mild solvent.
• Remove any remaining gasket from the
crankcase mating surface.
2. Check: • CrankcaseCrack/damage  Replace.
1
a

TRANSMISSION
6-80
2. Install:• Collar “1”
• 2nd wheel gear (26T) “2”
• 4th wheel gear (21T) “3”
• 3rd wheel gear (21T) “4”
• 5th wheel gear (21T) “5”
• Collar “6”
• 1st wheel gear (29T) “7”
• O-rings “8” (to the drive axle “9”)
TIP
• Before installation, apply molybdenum disul-fide oil to the inner and end surface of the idler
gear and the collar and to the inner surface of
the sliding gear, then install.
• Apply the lithium-soap-based grease on the
O-ring.
3. Install: • Washer “1”
• Circlip “2”
TIP
• Be sure the circlip sharp-edged corner “a” is positioned opposite side to the washer and
gear “b”.
• Install the circlip with its ends “c” settled even-
ly on the spline crests. 4. Install:
• Collar “1”
TIP
• Apply the lithium-soap-based grease on the oil seal lip.
• When installing the collar into the crankcase, pay careful attention to the crankcase oil seal
lip.
5. Install: • Main axle “1”
• Drive axle “2”
TIP
• Install to the left crankcase simultaneously.
• Apply engine oil to the main axle and the drive
axle bearing.
New
2 9
8
3
4
5
6
7
New
MM
LS
M
1
New
2 1
2
ab
cc
1
2
EE

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