2016 YAMAHA WR 450F brake

FRONT FORK
5-40
EAS2GC1197
FRONT FORK
Removing the front fork legs
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Front wheel Refer to “FRONT WHEEL” on page 5-4.
Front brake caliper Refer to “FRONT BRAKE” on page 5-13.
1 Brake hose holder 2
2 Protector 1
3 Upper bracket pinch bolts 2 Loosen.
4 Damper assembly 1 Loosen.
5 Lower bracket pinch bolts 2 Loosen.
6 Front fork leg 1
7 Reflector/Stay/Nut 1 For Canada
For installation, reverse the removal proce-
dure.

SWINGARM
5-65
EAS2GC1216
SWINGARM
Removing the swingarm
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Brake hose holder Refer to “REAR BRAKE” on page 5-23.
Rear brake caliper Refer to “REAR BRAKE” on page 5-23.
Bolt (brake pedal)
Drive chain
1 Collars
2
2 Oil seals
2
3 Thrust bearing
2
4 Bushing
2
5 Oil seals
2
6 Bearing
4
For installation, reverse the removal proce-
dure.
1
2
3
6
4
6
4
1
3
6
2
5
T.R.70 Nm (7.0 mlbf)
kgf, 51 ft
T.R.4.0 Nm (0.40 mlbf)
kgf, 2.9 ft

6
ENGINE
ENGINE REMOVAL......................................................................................... 6-1
REMOVING THE SILENCER ..................................................................... 6-6
REMOVING THE EXHAUST PIPE 2.......................................................... 6-6
REMOVING THE DRIVE SPROCKET ....................................................... 6-6
REMOVING THE ENGINE ......................................................................... 6-7
CLEANING THE SPARK ARRESTER ....................................................... 6-7
CHECKING THE SILENCER AND EXHAUST PIPE.................................. 6-8
INSTALLING THE ENGINE........................................................................ 6-8
INSTALLING THE BRAKE PEDAL ............................................................ 6-9
INSTALLING THE DRIVE SPROCKET...................................................... 6-9
INSTALLING THE EXHAUST PIPE AND MUFFLER................................. 6-9
CAMSHAFT .................................................................................................... 6-11
REMOVING THE CAMSHAFT ................................................................. 6-13
CHECKING THE CAMSHAFT.................................................................. 6-14
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .......... 6-15
CHECKING THE TIMING CHAIN TENSIONERS .................................... 6-15
CHECKING THE DECOMPRESSION SYSTEM.............. ........................ 6-16
INSTALLING THE CAMSHAFTS ............................................................. 6-16
CYLINDER HEAD ........................................................................................... 6-18
REMOVING THE CYLINDER HEAD........................................................ 6-20
CHECKING THE TIMING CHAIN GUIDE (INTAKE SIDE) ...................... 6-20
CHECKING THE CYLINDER HEAD ........................................................ 6-20
INSTALLING THE CYLINDER HEAD ...................................................... 6-21
VALVES AND VALVE SPRINGS ................................................................... 6-23
REMOVING THE VALVES ....................................................................... 6-24
CHECKING THE VALVES AND VALVE GUIDES ................................... 6-25
CHECKING THE VALVE SEATS ............................................................. 6-26
CHECKING THE VALVE SPRINGS......................................................... 6-28
CHECKING THE VALVE LIFTERS .......................................................... 6-29
INSTALLING THE VALVES ..................................................................... 6-29
CYLINDER AND PISTON ............................................................................... 6-31
REMOVING THE PISTON ....................................................................... 6-32
CHECKING THE CYLINDER AND PISTON ............................................ 6-32
CHECKING THE PISTON RINGS............................................................ 6-33
CHECKING THE PISTON PIN ................................................................. 6-34
INSTALLING THE PISTON AND CYLINDER .......................................... 6-34
ELECTRIC STARTER .................................................................................... 6-36
CHECKING THE STARTER MOTOR ...................................................... 6-38
ASSEMBLING THE STARTER MOTOR .................................................. 6-39

ENGINE REMOVAL
6-4
Removing the engine
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
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.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 6-1.
Air filter case Refer to “THROTTLE BODY” on page 8-7.
Throttle body Refer to “THROTTLE BODY” on page 8-7.
Clutch cable Refer to “CLUTCH” on page 6-41.
Shift pedal Refer to “SHIFT SHAFT” on page 6-53.
Starter motor Refer to “ELECTRIC STARTER” on page 6-
36.
1 Engine guard 1
2 Brake pedal 1
3Spring 1
4 Cylinder head breather hose 1
New
New
LS
M
8
8
76
11
4 5
New
1
10
3 2 9
55 Nm (5.5 m kgf, 40 ft Ibf)T.R.

ENGINE REMOVAL
6-6
EAS2GC1227REMOVING THE SILENCER
1. Remove:• Rear shock absorber assembly lower bolt “1”
• Connecting arm bolt (relay arm side) “2”
• Silencer “3”
TIP
Move the rear shock absorber to the left side of
the chassis, and remove the silencer.
EAS2GC1228REMOVING THE EXHAUST PIPE 2
1. Remove: • Starter motor
Refer to “ELECTRIC STARTER” on page 6-
36.
• Exhaust pipe 2
TIP
Put the Exhaust pipe 2 into the state as shown
by moving this, and then remove it.
EAS2GC1229REMOVING THE DRIVE SPROCKET
1. Straighten the lock washer tab.
2. Remove:
• Nut (drive sprocket) “1”
• Lock washer “2”
TIP
Loosen the nut while applying the rear brake.
3. Remove:• Drive sprocket “1”
• Drive chain “2”
TIP
Remove the drive sprocket together with the
drive chain.
1 2
3

ENGINE REMOVAL
6-9
EAS2GC1234INSTALLING THE BRAKE PEDAL
1. Install:• Spring “1”
• Brake pedal “2”
• O-rings “3”
• Bolt (brake pedal) “4”
•Clip “5”
TIP
Apply the lithium-soap-based grease on the
bolt, O-rings and brake pedal bracket.
EAS2GC1235INSTALLING THE DRIVE SPROCKET
1. Install:• Drive sprocket “1”
• Drive chain “2”
TIP
Install the drive sprocket together with the drive
chain.
2. Install:• Lock washer “1”
• Nut (drive sprocket) “2”
TIP
Tighten the nut while applying the rear brake.
ECA
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is
fastened together.
3. Bend the lock washer tab to lock the nut.
4. Install:• Drive sprocket guide
• Drive sprocket cover “1”
• Bolt (drive sprocket cover) “2”
EAS2GC1236INSTALLING THE EXHAUST PIPE AND
MUFFLER
1. Install:•Gasket
• Exhaust pipe 1 “1”
• Nut (exhaust pipe 1) “2”
TIP
First temporarily tighten all nuts to 7 Nm (0.7
m·kgf, 5.1 ft·lbf). Then retighten them to 10 Nm
(1.0 m·kgf, 7.2 ft·lbf).
Bolt (brake pedal)
26 Nm (2.6 m·kgf, 19 ft·lbf)
Nut (drive sprocket) 75 Nm (7.5 m·kgf, 54 ft·lbf)
New
T R..
1
2
3 4 5
LS
New
T R..
Bolt (drive sprocket cover)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Nut (exhaust pipe) 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
2 1
New
T R..

CLUTCH
6-41
EAS2GC1265
CLUTCH
Removing the clutch
OrderPart name Q’tyRemarks
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Brake pedal Refer to “ENGINE REMOVAL” on page 6-1.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3 O-ring 1
4 Clutch spring 6
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8Washer 1
9 Bearing 1
10 Ball 1
11 Push rod 2 1
12 Friction plate 1 3
13 Clutch plate 1 4 Thickness:2.0 mm (0.079 in)
LS
New
New
New
2
3
4
5
78 9
610 11
12
12
20
1
14
16
13
15 19
18
17
T.R.
T.R.
T.R.
T.R.
LT
(2) (5) (6)

CLUTCH
6-43
Removing the right crankcase cover
OrderPart name Q’tyRemarks
Engine guard Refer to “ENGINE REMOVAL” on page 6-1.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
Brake pedal Refer to “ENGINE REMOVAL” on page 6-1.
Clutch cover Refer to “CLUTCH” on page 6-41.
1 Oil filter element cover 1
2 Oil filter element 1
3 Radiator pipe 2 1
4 Kickstarter lever 1
5 Right crankcase cover 1
6 Gaskets 1
7 Dowel pin 2
8Collar 1
For installation, reverse the removal proce-
dure.
T.R.
LS
New
New
67
2
5
4
1
7
8
New
3
LS
New
New
LS
LS
NewNew
LT
LS