2016 YAMAHA WR 450F key

EAS2GC1003
INTRODUCTION
Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama-
ha's vast experience in the production of pacesetting racing machines. It represents the highest
grade of craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you
have any questions about this manual or your machine, please contact your Yamaha dealer.
The design and manufacture of this Yamaha machine fully comply with the emissions standards for
clean air applicable at the date of manufacture. Yamaha has met these standards without reducing
the performance or economy of operation of the machine. To maintain these high standards, it is im-
portant that you and your Yamaha dealer pay close attention to the recommended maintenance
schedules and operating instructions contained within this manual.
TIP
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor
discrepancies between your machine and this ma nual. If you have any questions concerning this
manual, please consult your Yamaha dealer.
EWA
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-
TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EAS2GC1004
IMPORTANT MANUAL INFORMATION
Particularly important informat ion is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP

OIL PUMP AND BALANCER GEAR
6-58
Removing the balancer
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
Right crankcase cover Refer to “CLUTCH” on page 6-41.
Generator rotor Refer to “GENERATOR AND STARTER
CLUTCH” on page 6-63.
1 Nut (balancer) 1
2 Nut (primary drive gear) 1
3 Nut (balancer shaft driven gear) 1
4 Lock washer 1
5Balancer 1
6 Straight key 1
7 Conical washer 1
8 Primary drive gear 1
9 Balancer shaft drive gear 1
10 Lock washer 1
11 Balancer weight gear 1
For installation, reverse the removal proce-
dure.
45 Nm (4.5 m kgf, 33 ft Ibf)T.R.
100 Nm (10 m kgf, 72 ft lbf)T.R.
50 Nm (5.0 m kgf, 36 ft Ibf)T.R.
New
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
11
LT

OIL PUMP AND BALANCER GEAR
6-61
EAS2GC1304INSTALLING THE OIL PUMP AND BALANC-
ER GEAR
1. Install:• Oil pump assembly “1”
• Oil pump assembly bolt “2”
ECA1DX1023
NOTICE
After tightening the bolts, make sure that
the oil pump turns smoothly.
2. Install:• Balancer weight gear “1”
TIP
Install the balancer weight gear and balancer
shaft with their lower sp lines “a” aligning with
each other.
3. Install:
• Balancer drive gear “1”
TIP
• Align the punched mark “a” on the balancer drive gear with the punched mark “b” on the
balancer weight gear.
• Install the balancer drive gear and crankshaft with the lower splines “c” aligning with each
other. 4. Install:
• Lock washer “1”
• Balancer weight gear nut “2”
• Primary drive gear “3”
• Conical washer “4”
• Primary drive gear nut “5”
• Straight key “6”
•Balancer “7”
• Lock washer “8”
• Balancer nut “9”
TIP
• Apply engine oil to the contact surface and threaded portion of the primary drive gear nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Place an aluminum plate “a” between the teeth of the balancer drive gear “10” and bal-
ancer weight gear “11”.
• Install the conical wash er with its convex sur-
face “b” outward.
Oil pump assembly bolt
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
LOCTITE®
T R..
1
2
LT
Balancer weight gear nut50 Nm (5.0 m·kgf, 36 ft·lbf)
Primary drive gear nut 100 Nm (10 m·kgf, 72 ft·lbf)
Balancer nut 45 Nm (4.5 m·kgf, 33 ft·lbf)
ba
New
T R..
New
T R..
New
T R..

GENERATOR AND STARTER CLUTCH
6-63
EAS2GC1305
GENERATOR AND STARTER CLUTCH
Removing the generator
Order Job/Parts to remove Q’tyRemarks
Drain the engine oil. Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Seat and fuel tank Refer to “GENERAL CHASSIS” on page 5-1
and “FUEL TANK” on page 8-1.
Disconnect the AC magneto lead.
Clutch cable
Shift pedal Refer to “SHIFT SHAFT” on page 6-53.
1 Cover (Damper assembly) 1
2 Damper assembly 1
3 Left crankcase cover 1
4Gasket 1
5 Dowel pin 2
6 Starter idle gear 1
7 Bearing 1
8 Starter idle gear shaft 1
9 Generator rotor 1
10 Woodruff key 1
T R..
T R..
T R..
5
5 10
87
6
21
13 3
4
11 9
12
T R..
T R..
T R..LT
LT
T R..
T R..
14
LT
LT

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

GENERATOR AND STARTER CLUTCH
6-67
3. Install:• Starter clutch “1”To generator rotor “2”.
EAS2GC1309INSTALLING THE GENERATOR
1. Install:
• Woodruff key “1”
• Generator rotor “2”
TIP
• Clean the contact surfaces of the tapered por-tions of the crankshaft and generator rotor.
• When installing the woodruff key, make sure that its flat surface “a” is in parallel with the
crankshaft center line “b”.
• When installing the generator rotor, align the keyway “c” of the generator rotor with the
woodruff key.
2. Install: • Washer
• Generator rotor nut “1” 3. Install:
• Starter idle gear shaft “1”
• Bearing “2”
• Starter idle gear 2 “3”
TIP
Apply the engine oil on the starter idle gear
shaft, bearing and idle gear inner circumfer-
ence.
4. Install:
• Dowel pin
• Crankcase cover gasket
• Left crankcase cover “1”
• Lead holder “2”
• Crankcase cover bolt
• Neutral switch lead “3”
TIP
• Pass the AC magneto lead “4” under the left crankcase cover “a” as shown.
• Tighten the bolts in stage, using a crisscross
pattern.
Starter clutch bolt
16 Nm (1.6 m·kgf, 12 ft·lbf)
LOCTITE®
Generator rotor nut 65 Nm (6.5 m·kgf, 47 ft·lbf)
21
LT
T R..
2
C
1 1
1a
b
T R..
Crankcase cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
1
2 1
2
3
New
T R..

TROUBLESHOOTING
10-1
EAS2GC1406
TROUBLESHOOTING
EAS2GC1407GENERAL INFORMATION
TIP
The following guide for troubleshooting does
not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic
troubleshooting. Refer to the relative procedure
in this manual for checks, adjustments, and re-
placement of parts.
EAS2GC1408STARTING FAILURES
Engine
1. Cylinder and cylinder head• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
2. Piston and piston ring(s) • Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
3. Air filter • Improperly installed air filter
• Clogged air filter element
4. Crankcase and crankshaft • Improperly assembled crankcase
• Seized crankshaft
Fuel system
1. Fuel tank • Empty fuel tank
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose
2. Fuel pump
• Faulty fuel pump
3. Throttle body • Deteriorated or contaminated fuel
• Sucked-in air Electrical system
1. Battery
• Discharged battery
• Faulty battery
2. Fuse • Blown, damaged or incorrect fuse
• Improperly installed fuse
3. Spark plug • Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
4. Ignition coil • Cracked or broken ignition coil body
• Broken or shorted primary or secondary coils
5. Ignition system • Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
6. Switches and wiring
• Faulty ECU
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Improperly grounded circuit
• Loose connections
7. Starting system • Faulty starter motor
• Faulty starter relay
• Faulty starting circuit cut-off relay
• Faulty starter clutch
EAS2GC1409INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder and cylinder head• Incorrect valve clearance
• Damaged valve train components
2. Air filter • Clogged air filter element
Fuel system
1. Throttle body • Damaged or loose throttle body joint
• Improperly synchronized throttle bodies
• Improper throttle cable free play
• Flooded throttle body

TROUBLESHOOTING
10-2
Electrical system
1. Battery• Discharged battery
• Faulty battery
2. Spark plug • Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
3. Ignition coil
• Broken or shorted primary or secondary coil
• Cracked or broken ignition coil
4. Ignition system • Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
EAS2GC1410POOR MEDIUM-AND-HIGH-SPEED PER-
FORMANCE
Refer to “STARTING FAILURES” on page 10-
1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump • Faulty fuel pump
2. Throttle body
• Defective throttle body
3. ECU • Faulty ECU
EAS2GC1411SHIFTING IS DIFFICULT
Refer to “CLUTCH” on page 6-41.
EAS2GC1412SHIFT PEDAL DOES NOT MOVE
Engine
1. Shift shaft
• Bent shift shaft
2. Shift drum and shift forks • Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
3. Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EAS2GC1413
JUMPS OUT OF GEAR
Engine
1. Shift shaft• Incorrect shift pedal position
• Improperly returned stopper lever
2. Shift forks
• Worn shift fork
3. Shift drum • Incorrect axial play
• Worn shift drum groove
4. Transmission • Worn gear dog
EAS2GC1414CLUTCH SLIPS
Engine
1. Clutch• Improperly assembled clutch
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
EAS2GC1415CLUTCH DRAGS
Engine
1. Clutch• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Damaged clutch boss
• Burnt primary driven gear bushing
2. Engine oil • Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS2GC1416OVERHEATING
Engine
1. Cylinder head and piston• Heavy carbon buildup
• Clogged coolant passages
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality