2016 YAMAHA WR 450F engine oil

WATER PUMP
7-4
EAS2GC1332
WATER PUMP
Removing the water pump
OrderPart name Q’tyRemarks
Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Right crankcase cover Refer to “CLUTCH” on page 6-41.
1 Water pump housing 1
2 Dowel pin 2
3Gasket 1
4Collar 1
5Pin 1
6 Impeller shaft assembly 1
7 Oil seal 1
8 Bearing 1
9 Oil seal 1
For installation, reverse the removal proce-
dure.
LS
LS
7
6
2 2
3
1
854
New
New
New
E
9
New
E
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.

WATER PUMP
7-5
EAS2GC1333REMOVING THE OIL SEAL
TIP
• Remove the oil seal when the coolant level changes frequently more than usual, coolant
has discolored, or engine oil has become
milky.
• Do not use the removed oil seal.
1. Remove:• Oil seals “1”
EAS2GC1334CHECKING THE WATER PUMP
1. Check:
• Water pump housing cover
• Impeller shaftCracks/damage/wear  Replace.
EAS2GC1335CHECKING THE BEARING
1. Check:
• BearingRotate the inner race with your finger.
Rough spot/seizure  Replace.
EAS2GC1336INSTALLING THE OIL SEAL
1. Install:
• Oil seals “1”
TIP
• Apply the lithium-soap-based grease on the oil seal lip.
• Install the oil seal with its manufacture’s marks or numbers facing the right crankcase
cover “2”. 2. Install:
• Bearing “1”
TIP
Install the bearing by pressing its outer race
parallel.
EAS2GC1337ASSEMBLING THE WATER PUMP
1. Install:
• Impeller shaft assembly “1”
•Pin “2”
• Collar “3”
• Circlip “4”
TIP
• Take care so that the oil seal lip is not dam-aged or the spring does not slip off its posi-
tion.
• When installing the impeller shaft, apply the engine oil to the oil seal lip, the bearing, and
the impeller shaft.
1
1
New
1
1New
New
LS
LS2
New
4
1
23New
E

THROTTLE BODY
8-7
EAS2GC1351
THROTTLE BODY
Removing the throttle body
OrderPart name Q’tyRemarks
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
ECU Refer to “ENGINE REMOVAL” on page 6-1.
Ignition coil Refer to “ENGINE REMOVAL” on page 6-1.
1 Intake air temperature sensor coupler 1 Disconnect.
2 Breather hose 3 1
3 Air filter case 1
4 Fuel injector coupler 1 Disconnect.
5 Intake air pressure sensor coupler 1 Disconnect.
6 Throttle position sensor coupler 1 Disconnect.
7 Throttle cable cover 1
8 Throttle cable 2
3
1
2
7
11
12
10
9
4
8
6
5
3.5 Nm (0.35 m kgf, 2.5 ft Ibf)T.R.
3.5 Nm (0.35 m kgf, 2.5 ft Ibf)T.R.
7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.
3.0 Nm (0.30 m kgf, 2.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.

IGNITION SYSTEM
9-3
1. Joint connector
2. Joint connector
4. AC magneto
9. Battery
10.Frame ground
11.Starter relay
12.Main fuse
22.ECU (engine control unit)
23.Ignition coil
24.Spark plug
30.Joint connector
35.Lean angle sensor
36.Engine stop switch
48.Frame ground
49.Ignition coil sub-lead
50.Negative battery lead

IGNITION SYSTEM
9-4
EAS2GC1360TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
Before troubleshooting, remove the following part (s):
1. Seat
2. Side cover (left/right)
3. Air scoop (left/right)
4. Fuel tank
5. Air filter case cover1. Check the fuse. Refer to “CHECKING THE FUSES”
on page 9-68. NG

Replace the fuse(s).
OK 
2. Check the battery. Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69. NG

• Clean the battery terminals.
• Recharge or replace the battery.
OK 
3. Check the spark plug. Refer to “CHECKING THE SPARK
PLUG” on page 3-40. NG

Re-gap or replace the spark plug.
OK 
4. Check the ignition spark gap. Refer to “CHECKING THE IGNI-
TION SPARK GAP” on page 9-73. OK

The ignition system is normal.
NG 
5. Check the ignition coil. Refer to “CHECKING THE IGNI-
TION COIL” on page 9-74. NG

Replace the ignition coil.
OK 
6. Check the crankshaft position sen- sor.
Refer to “CHECKING THE CRANK-
SHAFT POSITION SENSOR” on
page 9-74. NG

Replace the stator assembly.
OK 
7. Check the engine stop switch. Refer to “CHECKING THE
SWITCHES” on page 9-64. NG

Replace the engine stop switch.
OK 

FUEL INJECTION SYSTEM
9-30
EAS2GC1375ECU SELF-DIAGNOSTIC FUNCTION
The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system
is operating normally. If this function detects a malfunction in the system, it immediately operates the
engine under substitute characteristics and illuminat es the engine trouble warning light to alert the
rider that a malfunction has occurred in the syst em. Once a malfunction has been detected, a fault
code number is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes while the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by th e self-diagnostic function, the ECU provides an ap-
propriate substitute characteristic operation, and al erts the rider of the detected malfunction by illu-
minating the engine trouble warning light.
Engine trouble warning light indication and fuel injection system operation
* The warning light flashes when any one of the foll owing conditions is present and the start switch
is pushed:
Checking the engine trouble warning light
The engine trouble warning light comes on for around 2 seconds when pushing the start switch to
turn on the meter light and the engine trouble warning light comes on while the start switch is being
pushed. Warning light indica-
tion ECU operation Fuel injection opera-
tion Vehicle operation
Flashing* Warning provided when unable to start
engine Operation stopped Cannot be operated
Remains on Malfunction detected Operated with substi- tute characteristics in
accordance with the
description of the mal-
functionCan or cannot be oper-
ated depending on the
fault code
12: Crankshaft position sensor 41: Lean angle sensor (open or short circuit)
30: Lean angle sensor (latch up detected) 50: ECU internal malfunction
(faulty ECU memory)
33: Ignition coil (Malfunction detected in the primary wire
of the ignition coil)
a. The meter light does not come on.
b. The meter light comes on.
c. Light OFF
d. Light ON for 2 seconds
ab
cd c

FUEL INJECTION SYSTEM
9-31
ECU detects an abnormal signal from a sensor
If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu-
minates the engine trouble warning light and provides the engine with alternate operating instructions
that are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS2GC1376TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check: • Fault code number
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 9-32.
b. Check the fault code number disp layed on the Yamaha diagnostic tool.
c. Identify the faulty system with the fault code number.
d. Identify the probable cause of the malfunction.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of the malfunction.
3. Perform the reinstatement action for the fuel injection system. Refer to “Confirmation of service
completion” in the appropriate table in “TROUBLESHOOTING DETAILS” on page 9-35.
4. After pushing the engine stop switch, push the start switch to check whether the fault code no. is
displayed.
TIP
If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is dis-
played.
5. Erase the malfunction history in the diagnostic mode. Refer to “SENSOR OPERATION TABLE”
(Diagnostic code No.62).
TIP
Turning off the meter light will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors an d actuators in the diagnostic mode. Refer to
“TROUBLESHOOTING DETAILS” on page 9-35.
If a malfunction is detected in the sensors or ac tuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and ac tuators, check and repair the inner parts of the
engine. Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOT-
ING DETAILS” on page 9-35.
Monitor the operation of the sensors and actua-
tors in the diagnostic mode. Refer to “TROU-
BLESHOOTING DETAILS” on page 9-35 and
“LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE
ACTIONS” on page 10-5. Check and repair.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Injector

FUEL INJECTION SYSTEM
9-45
2 Installed condition of lean an-gle sensor. Check the installed direction
and condition of the sensor. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 3.
3 Defective lean angle sensor. Execute the diagnostic mode. (Code No. 08)
Replace if defective.
Refer to “CHECKING THE
LEAN ANGLE SENSOR” on
page 9-75.Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 4.
4 Malfunction in ECU. Replace the ECU.
Fault code No. 33
Item Ignition coil: open or short circuit detected in the primary lead
of the ignition coil.
Fail-safe system Unable to start engine
Unable to drive vehicle
Diagnostic code No. 30
Actuation Actuates the ignition coil five times at one-second intervals.
The engine trouble warning light and the “WARNING” on the
Yamaha diagnostic tool screen come on each time the ignition coil
is actuated.
Procedure Check that a spark is generated five times.
• Connect an ignition checker.
Item Probable cause of malfunc-
tion and check Maintenance jobConfirmation of service
completion
1 Connection of ignition coil coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins). Improperly connected

Connect the coupler securely
or repair/replace the wire har-
ness. Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 2.
2 Connection of wire harness ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins). Improperly connected

Connect the coupler securely
or repair/replace the wire har-
ness. Start the engine and let it idle
for approximately 5 seconds.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 3.
Fault code No.
30
Item Latch up detected.