2016 YAMAHA WR 450F dimensions

GENERAL SPECIFICATIONS
2-1
EAS2GC1061
GENERAL SPECIFICATIONS
ModelModel 2GC1 (USA) 2GC2 (CAN)
2GC3 (EUR)
2GC4, 2GC5 (AUS) (NZL) (ZAF)
DimensionsOverall length 2165 mm (85.2 in)
Overall width 825 mm (32.5 in)
Overall height 1280 mm (50.4 in)
Seat height 965 mm (38.0 in)
Wheelbase 1465 mm (57.7 in)
Ground clearance 325 mm (12.80 in)
WeightCurb weight 123 kg (271 lb)

ENGINE SPECIFICATIONS
2-3
Cylinder headCombustion chamber volume 25.98–26.78 cm3 (1.59–1.63 cu.in)
Warpage limit 0.05 mm (0.0020 in)
Camshaft Drive system Chain drive (left)
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in)
Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in)
Camshaft-journal-to-camshaft-cap cl earance 0.028–0.062 mm (0.0011–0.0024 in)
Camshaft lobe dimensions
Lobe height (Intake) 37.630–37.730 mm (1.4815–1.4854 in)
Limit 37.530 mm (1.4776 in)
Base circle diameter (intake) 27.950–28.050 mm (1.1004–1.1043 in)
Limit 27.850 mm (1.0965 in)
Lobe height (Exhaust) 33.870–33.970 mm (1.3335–1.3374 in)
Limit 33.770 mm (1.3295 in)
Base circle diameter (Exhaust) 24.711–24.811 mm (0.9729–0.9768 in)
Limit 24.611 mm (0.9689 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Timing chain Tensioning system Automatic
Valve, valve seat, valve guide
Valve clearance (cold) Intake 0.13–0.20 mm (0.0051–0.0079 in)
Exhaust 0.18–0.25 mm (0.0071–0.0098 in)
Valve dimensions
Valve head diameter (intake) 36.90–37.10 mm (1.4528–1.4606 in)
Valve head diameter (exhaust) 30.40–30.60 mm (1.1968–1.2047 in)
Valve face width (intake) 1.697 mm (0.0668 in)
Valve face width (exhaust) 1.768 mm (0.0696 in)
Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Valve seat contact width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness (intake) 1.20 mm (0.0472 in)
Valve margin thickness (exhaust) 0.85 mm (0.0335 in)
Valve stem diameter (intake) 5.475–5.490 mm (0.2156–0.2161 in)
Limit 5.445 mm (0.2144 in)
Valve stem diameter (exhaust) 5.465–5.480 mm (0.2152–0.2157 in)
Limit 5.435 mm (0.2140 in)
Valve guide inside diameter (intake) 5.500–5.512 mm (0.2165–0.2170 in)
Limit 5.550 mm (0.2185 in)
Valve guide inside diameter (exhaus t) 5.500–5.512 mm (0.2165–0.2170 in)
Limit 5.550 mm (0.2185 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.020–0.047 mm (0.0008–0.0019 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)

ENGINE SPECIFICATIONS
2-4
Valve springFree length (intake) 40.76 mm (1.60 in)
Limit 38.72 mm (1.52 in)
Free length (exhaust) 36.94 mm (1.45 in)
Limit 35.09 mm (1.38 in)
Installed length (intake) 34.78 mm (1.37 in)
Installed length (exhaust) 30.83 mm (1.21 in)
Spring rate K1 (intake) 31.90 N/mm (3.25 kgf/mm, 182.15 lbf/in)
Spring rate K2 (intake) 41.37 N/mm (4.22 kgf/mm, 236.22 lbf/in)
Spring rate K1 (exhaust) 21.76 N/mm (2.22 kgf/mm, 124.25 lbf/in)
Spring rate K2 (exhaust) 28.12 N/mm (2.87 kgf/mm, 160.57 lbf/in)
Installed compression spring force (intake) 178.00–204.00 N (18.15–20.80 kgf,
40.01–45.86 lbf)
Installed compression spring force (exhaust) 124.00–142.00 N (12.64–14.48 kgf,
27.88–31.92 lbf)
Spring tilt (intake) 2.5 °/1.8 mm (2.5 °/0.07 in)
Spring tilt (exhaust) 2.5 °/1.6 mm (2.5 °/0.06 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder Bore 97.000–97.010 mm (3.8189–3.8193 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
PistonPiston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in)
Limit 0.15 mm (0.006 in)
Diameter 96.955–96.970 mm (3.8171–3.8177 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Offset 0.00 mm (0.0000 in)
Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in)
Limit 18.045 mm (0.7104 in)
Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in)
Limit 17.971 mm (0.7075 in)
Piston ringTop ring Ring type Barrel
Dimensions (B  T) 1.00  3.30 mm (0.04  0.13 in)
End gap (installed) 0.20–0.30 mm (0.0079–0.0118 in)
Limit 0.55 mm (0.0217 in)
Ring side clearance 0.015–0.065 mm (0.0006–0.0026 in)
Limit 0.120 mm (0.0047 in)
2nd ring Ring type Taper
Dimensions (B  T) 1.00  3.10 mm (0.04  0.12 in)
End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in)
Limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.060 mm (0.0008–0.0024 in)
Limit 0.120 mm (0.0047 in)
Oil ring
Dimensions (B  T) 1.50  2.25 mm (0.06  0.89 in)
End gap (installed) 0.20–0.50 mm (0.0079–0.0197 in)

CABLE ROUTING DIAGRAM
2-36
1. Clamp
2. Throttle position sensor lead
3. Joint coupler
4. Intake air temperature sensor lead
5. Intake air pressure sensor lead
6. Wire harness
7. Injector lead
8. Injector coupler
9. Throttle body
10. Cylinder head breather hose
11. Engine ground sub-lead
12. Plate
13. Engine ground sub-lead coupler
14. Starter motor lead
15. Plastic band
16. Fuel sender coupler
17. High tension cord
18. Spark plug cap
19. Cylinder head cover
20. Fuel hose
21. Fuel sender
22. Sub-wire harness
23. Radiator breather hose
24. Radiator hose
25. Down tube
26. Starter motor cover
27. Starter motor
28. AC magneto lead
29. Clutch cable
30. Neutral switch lead
31. Radiator
32. Breather hose clamp
33. Grommet (high tension cord)
34. ECU
35. Air filter case
36. Sub-wire harness coupler
37. Engine bracket
A. Fix the wire harness, clutch switch lead and start switch lead by the plasti c clamp, and insert the
projection of the plastic clamp into the hole in the
sheet metal of the radiator.
B. Route each lead so that the leads are not pinched between the tank rail and air filter joint.
C. Insert the projection of the wire harness into the hole in the frame.
D. Pass the cylinder head breather hose between the throttle cable and engine ground sub-lead.
E. Insert the engine ground sub-lead coupler into the plate, facing inside the vehicle.
F. Connect the sub-wire harness to the wire har- ness.
G. Pass the high tension cord above the fuel hose.
H. ±10°
I. Install the spark plug cap with this facing the right
of the vehicle.
J. Push the spark plug cap home, where there shall be no gap between it and the cylinder head cover.
K. Pass the radiator breather hose between the down tubes.
L. Pass the starter motor lead under the starter mo- tor shaft.
M. Pass the sub-wire harness between the ECU and the air filter case.
N. Apply adhesive to the s lit and inside of the grom-
met, and then fix the grommet according to the
specified dimensions.
O. 50±3 mm (2.0±0.12 in)
P. Insert the coupler of the sub-wire harness into the
rib of the air filter case. Q. Clamp the starter motor lead, point the clamp
downward, and insert it into the frame.
R. Route the radiator breather hose through be- tween the radiator hose, down tube and engine
bracket.

HANDLEBAR
5-37
5. Install:• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
•Clamp “4”
TIP
• The engine stop switch, the clutch lever, and the clutch lever holder should be installed ac-
cording to the dimensions shown.
• Pass the engine stop switch lead through the
middle of the clutch lever holder.
6. Install: • Right grip “1”
• Collar “2”Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the grip match mark “b” and tube guide slot “c”
form the angle as shown. 7. Install:
• Rubber cover “1”
• Throttle grip “2”
TIP
Apply the lithium-soap-based grease on the
throttle grip sliding surface.
8. Install:• Throttle cables “1”
TIP
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle-
bar.
9. Install:
• Throttle cable housings “1”
• Screw (throttle cable housings) “2”
EWA
Engine stop switch screw0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
Screw (throttle cable housings)3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
64
1 b
c
3
64
T R..

CAMSHAFT
6-14
EAS2GC1239CHECKING THE CAMSHAFT
1. Check:• Camshaft lobes
Blue discoloration/pitting/scratches  Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “A” and “B”Out of specification  Replace the cam-
shaft. 3. Measure:
• Camshaft runout
Out of specification  Replace.
4. Measure: • Camshaft-journal-to-camshaft-cap clear-ance
Out of specification  Measure the cam-
shaft journal diameter.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder head.
b. Position a strip of Plastigauge® “1” onto the camshaft journal as shown.
Camshaft lobe dimensions
Lobe height (Intake)37.630–37.730 mm (1.4815–
1.4854 in)
Limit 37.530 mm (1.4776 in)
Base circle diameter (intake) 27.950–28.050 mm (1.1004–
1.1043 in)
Limit 27.850 mm (1.0965 in)
Lobe height (Exhaust) 33.870–33.970 mm (1.3335–
1.3374 in)
Limit 33.770 mm (1.3295 in)
Base circle diameter (Exhaust) 24.711–24.811 mm (0.9729–
0.9768 in)
Limit 24.611 mm (0.9689 in)
1
2
3
Camshaft runout limit 0.030 mm (0.0012 in)
Camshaft-journal-to-camshaft-
cap clearance 0.028–0.062 mm (0.0011–0.0024
in)
1