2016 YAMAHA WR 450F lock

OIL PUMP AND BALANCER GEAR
6-62
5. Bend the lock washer tab.
12
11
10
a
3 45
10 11
a
b
3

GENERATOR AND STARTER CLUTCH
6-65
EAS2GC1306REMOVING THE GENERATOR
1. Remove:• Generator rotor nut “1”
• Washer
2. Remove: • Generator rotor “1”
(with the rotor puller “2”)
• Woodruff key
EAS2GC1307CHECKING THE STARTER CLUTCH
1. Check: • Starter clutch rollers
Damage/wear  Replace.
2. Check: • Starter clutch idle gear
• Starter clutch gearBurrs/chips/roughness/wear  Replace the
defective part (s). 3. Check:
• Starter clutch gearDamage/pitting/wear  Replace the starter
clutch gear.
4. Check: • Damper assembly
Damage/pitting/wear  Replace the damp-
er assembly.
Check the gear of the starter motor arma-
ture.
5. Check: • Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear “1” onto the starter clutch and hold the starter clutch.
b. When turning the starter clutch drive gear
clockwise “A”, the starter clutch and the
starter clutch drive gear should engage, oth-
erwise the starter clutch is faulty and must
be replaced.
c. When turning the starter clutch drive gear counterclockwise “B”, it should turn freely,
otherwise the starter clutch is faulty and
must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rotor puller90890-04142
Rotor puller YM-04142
1
1
2
1
A
B

FUEL INJECTION SYSTEM
9-35
6. ConditionThe current conditions are displayed. (Detected/Recovered)
7. Symptom
The symptoms of the detected malfunction are displayed.
8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed.
9. FFD (only for models that can display freeze frame data) The mark “ ” is displayed when the freeze frame data is available.
10.ECU conduction time (hour: minute: second)
The total ECU conduction time (total hours the vehicle’s start switch was ON) when the malfunc-
tion was detected is displayed.
11.Number of main switch operation after detection
The number of times the meter light comes on by pushing the start switch between the malfunction
detection and code reading is displayed.
12.Number of occurrences The number of malfunction occurrences between th e malfunction detection and code reading is
displayed.
EAS2GC1378TROUBLESHOOTING DETAILS
This section describes the measures per fault c ode number displayed on the diagnostic tool. Check
and service the items or components that are the probable cause of the malfunction following the or-
der given.
After the check and service of the malfunctioning part have been completed, reset the diagnostic tool
display according to the reinstatement method.
Fault code No.:
Fault code number displayed on the diagnostic tool when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated.
Fault code No. 12
Item Crankshaft position sensor: no normal signals are received
from the crankshaft position sensor.
Fail-safe system Unable to start engine
Unable to drive vehicle
Diagnostic code No. —
Diagnostic tool display —
Procedure —
Item Probable cause of malfunc-
tion and check Maintenance jobConfirmation of service
completion
1 Connection of crankshaft po- sition sensor 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. Crank the engine.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 2.

FUEL INJECTION SYSTEM
9-36
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. Crank the engine.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 3.
3 Wire harness continuity. Open or short circuit  Re-
place the wire harness.
Between the crankshaft posi-
tion sensor coupler and ECU
coupler.
black/blue–black/blue
gray–gray Crank the engine.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 4.
4 Installed condition of crank- shaft position sensor.
Check for looseness or
pinching.
Check the gap between the
crankshaft position sensor
and the pickup rotor. Improperly installed sensor

Reinstall or replace the
sensor.
Refer to “GENERATOR AND
STARTER CLUTCH” on
page 6-63. Crank the engine.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 5.
5 Defective crankshaft position sensor. Check the crankshaft position
sensor.
Refer to “CHECKING THE
CRANKSHAFT POSITION
SENSOR” on page 9-74. Crank the engine.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 6.
6 Malfunction in ECU. Replace the ECU. Fault code No. 12
Item Crankshaft position sensor: no normal signals are received
from the crankshaft position sensor.

FUEL INJECTION SYSTEM
9-37
TIP
• If fault code Nos. 13 and 14 are both displayed, perform the checks and maintenance jobs for fault
code No. 13 first.
• Before troubleshooting, disconnect the star ter motor lead from the starter relay.
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.
Fail-safe system Able to start engine
Able to drive vehicle
Diagnostic code No. 03
Diagnostic tool display Displays the intake air pressure.
Procedure Operate the throttle while pushing the start switch.(If the display
value changes, the performance is OK.)
Item Probable cause of malfunc-
tion and check Maintenance jobConfirmation of service
completion
1 Connection of intake air pres- sure sensor 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. Push the start switch.
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. 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 Wire harness continuity. Open or short circuit  Re-
place the wire harness.
Between intake air pressure
sensor coupler and ECU cou-
pler.
black/blue–black/blue
pink–pink
blue–blue 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 Installed condition of intake air pressure sensor.
Check for looseness or
pinching. Improperly installed sensor

Reinstall or replace 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 5.

FUEL INJECTION SYSTEM
9-39
TIP
Before troubleshooting, disconnect the starter motor lead from the starter relay.
2 Defective intake air pressure
sensor. Execute the diagnostic mode.
(Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
1000 m above sea level: Ap-
prox. 90 kPa
2000 m above sea level: Ap-
prox. 80 kPa
3000 m above sea level: Ap-
prox. 70 kPa
When engine is cranking:
Make sure that the indication
value changes.
The value does not change
when engine is cranking.

Check the intake air pressure
sensor.
Replace if defective.
Refer to “CHECKING THE
INTAKE AIR PRESSURE
SENSOR” on page 9-80.
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.
Fail-safe system Able to start engine
Able to drive vehicle
Diagnostic code No. 01
Diagnostic tool display Throttle position sensor signal
• 11–14 (fully closed position)
• 109–116 (fully open position)
Procedure • Check with throttle valve fully closed.
• Check with throttle valve fully open.
Item Probable cause of malfunc-
tion and check Maintenance jobConfirmation of service
completion
1 Connection of throttle posi- tion sensor 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. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 2.
Fault code No.
14
Item Intake air pressure sensor: hose system malfunction (clogged
or detached hose).

FUEL INJECTION SYSTEM
9-40
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. 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 Wire harness continuity. Open or short circuit  Re-
place the wire harness.
Between throttle position
sensor coupler and ECU cou-
pler.
black/blue–black/blue
yellow–yellow
blue–blue 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 Installed condition of throttle position sensor.
Check for looseness or
pinching. Improperly installed sensor

Reinstall or replace the
sensor.
Refer to “ADJUSTING THE
THROTTLE POSITION SEN-
SOR” on page 8-11. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 5.
5 Applied voltage of throttle po- sition sensor lead. Check the applied voltage.
(black/blue–blue)
Refer to “CHECKING THE
THROTTLE POSITION SEN-
SOR” on page 9-79. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 6.
Location of discon-
nected lead Output
voltage
Disconnected
ground lead 5V
Disconnected out-
put lead 0V
Disconnected
power supply lead 0V
6 Defective throttle position sensor. Check throttle position sen-
sor signal.
Execute the diagnostic mode.
(Code No. 01)
When the throttle valve is fully
closed:
A value of 11–14 is indicated.
When throttle valve is fully
open:
A value of 109–116 is indicat-
ed.
An indicated value is out of
the specified range.
 Re-
place the throttle position
sensor. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 7.
Fault code No. 15
Item
Throttle position sensor: open or short circuit detected.

FUEL INJECTION SYSTEM
9-42
TIP
• Make sure that the engine is completely cool before checking the coolant temperature sensor.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.
Fail-safe system Able to start engine
Able to drive vehicle
Diagnostic code No. 06
Diagnostic tool display Displays the coolant temperature.
Procedure Compare the actually measured coolant temperature with the
Yamaha diagnostic tool display value.
Item Probable cause of malfunc-
tion and check Maintenance jobConfirmation of service
completion
1 Connection of coolant tem- perature sensor 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. Push the start switch.
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. 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 Wire harness continuity. Open or short circuit  Re-
place the wire harness.
Between coolant temperature
sensor coupler and ECU cou-
pler.
green/white–green/white
black/blue–black/blue 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 Installed condition of coolant temperature sensor.
Check for looseness or
pinching. Improperly installed sensor

Reinstall or replace 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 5.