2016 YAMAHA WR 450F wheel

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
New

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

ELECTRICAL COMPONENTS
9-77
EAS2GC1396CHECKING THE SPEED SENSOR
1. Check:• Speed sensor output voltageOut of specification  Replace.
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a. Connect the test harness-speed sensor (3P)
to the speed sensor coupler and wire har-
ness.
b. Connect the pocket tester (DC20V) to the test harness-speed sensor (3P).
c. Push the start switch.
d. Elevate the front wheel and slowly turn it.
e. Measure the voltage (DC 5 V) of white and black/white. With the front wheel slowly ro-
tating, voltage alternates between 0 V and 5
V.
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EAS2GC1397CHECKING THE FUEL SENDER
1. Drain the gasoline.
2. Disconnect:• Fuel sender coupler
(from the fuel sender)
3. Remove:
• Fuel sender(from the fuel tank) 4. Check:
• Fuel sender resistanceOut of specification  Replace the fuel
sender.
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a. Connect the pocket tester (  1k) to the
fuel sender as shown.
b. Measure the resistance of the fuel sender.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1398CHECKING THE RESISTER
1. Disconnect: • Resister coupler(from the wire harness)
2. Check: • Resister resistanceOut of specification  Replace the resister.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (  10) to the re-
sister as shown.
Output voltage reading cycle
0.6V to 4.8V to 0.6V to 4.8V
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
Test harness– speed sensor 5TJ
(3P) 90890-03228
Test harness– speed sensor 5TJ
(3P) YU-03228
• Positive tester probe  White “1”
• Negative tester probe 
Black “2”
BRW
21
Fuel sender resistance
1.35–1.90 k  at 25°C (77°F)
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
• Positive tester probe  Green “1”
• Negative tester probe 
Black “2”
Resister resistance64.6–71.4 
Pocket tester 90890-03112
Analog pocket tester YU-03112-C
1
2

TROUBLESHOOTING
10-4
7. Wheel (s)• Incorrect wheel balance
• Broken or loose spoke
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame • Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
EAS2GC1422HEADLIGHT DOES NOT COME ON
Electrical system
1. Headlight• Fuse open circuit
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (start switch)
• Burnt-out headlight bulb
EAS2GC1423HEADLIGHT BULB BURNT OUT
Electrical system
1. Headlight
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty start switch
• Headlight bulb life expired
EAS2GC1424TAILLIGHT DOES NOT COME ON
Electrical system
1. Taillight• Wrong taillight LED
• Too many electrical accessories
• Incorrect connection
• Faulty battery

LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
10-6
SENSOR OPERATION TABLEDiag-
nostic code No. Item Display Procedure
01 Throttle position sensor sig- nal
• Fully closed position
• Fully opened position • 11–14
• 109–116 • Check with throttle valve
fully closed.
• Check with throttle valve fully open.
03 Intake air pressure Displays the intake air pres- sure.Operate the throttle while
pushing the start switch. (If
the display value changes,
the performance is OK.)
05 Intake air temperature Displays the intake air tem- perature.Compare the actually mea-
sured intake air tempera-
ture with the Yamaha
diagnostic tool display val-
ue.
06 Coolant temperature When engine is cold: Dis- plays temperature closer to
air temperature.
When engine is hot: Displays
current coolant temperature.Compare the actually mea-
sured coolant temperature
with the Yamaha diagnostic
tool display value.
07 Vehicle speed pulses Vehicle speed pulse 0–999Check that the number in-
creases when the front
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
08 Lean angle sensor • Upright
• Overturned Displays the output voltage.
• 0.4–1.4
• 3.7–4.4 Remove the lean angle
sensor, and incline it more
than 45 degrees.
09 Monitor voltage Displays the fuel system volt- age.
• Approximately 12.0 (V)—
21 Neutral switch • Gear in neutral
• Gear not in neutral •ON
•OFF Operate the shift pedal.
60 EEPROM fault code display • No fault
• CO adjustment value
• Setting tool adjustment values 0–8 for fuel injec-
tion amount or ignition tim-
ing •00
•01
•07
—
61 Malfunction history ( ) code No. display *1
• There is no history.
• There is some history. •00
• Other: Displays the fault
code of ( ). —