2016 YAMAHA WR 450F remove seats

CYLINDER HEAD
6-20
EAS2GC1245REMOVING THE CYLINDER HEAD
1. Remove:• Cylinder head bolts
TIP
• Loosen the bolts in the proper sequence as shown.
• Loosen each bolt 1/2 of a turn at a time. After
fully loosening all the bolts, remove them.
•M6  35 mm (1.38 in): “1” – “2”
• M10  149 mm (5.87 in): “3” – “6”
EAS2GC1246CHECKING THE TIMING CHAIN GUIDE (IN-
TAKE SIDE)
1. Check:
• Timing chain guide (intake side)Damage/wear  Replace.
EAS2GC1247CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
TIP
Use a rounded scraper, not a sharp instrument,
in order not to damage or scratch the spark
plug bore threads. 2. Check:
• Cylinder head
Damage/scratches  Replace.
TIP
When replacing the cylinder head, replace also
the valve.
Refer to “CHECKING THE VALVE SEATS” on
page 6-26.
• Cylinder head coolant passagesMineral deposits/rust  Eliminate.
3. Measure: • Cylinder head warpage
Out of specification  Resurface the cylin-
der head.
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a. Place a straightedge and a thickness gauge across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400–600 grit wet sandpaper on a
surface plate, and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, turn the cylinder
head several times.
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61
2
35
4
x2 x4
FWD
Warpage limit
0.05 mm (0.0020 in)

VALVES AND VALVE SPRINGS
6-24
EAS2GC1250REMOVING THE VALVES
TIP
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure that the valves are properly
sealed.
1. Remove:• Valve lifter “1”
• Adjusting pad “2”
TIP
• Place a cloth in the timing chain space to pre-vent adjusting pads from falling into the crank-
case.
• Make a note of the positions of valve lifters and adjusting pads so that they can be rein-
stalled in their original places.
2. Check: • Valve sealingLeakage at the valve seat  Check the
valve face, the valve seat, and the valve seat
contact width.
Refer to “CHECKING THE VALVE SEATS”
on page 6-26.
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a. Pour a clean solvent “a” into the intake and exhaust ports.
b. Check that the valves are properly sealed.
TIP
Check that there are no kerosene leaks from
the valve seat “1”.
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3. Remove: • Valve cotter “1”
TIP
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor adapter
“3”.
Valve lapper
90890-04101
Valve lapping tool YM-A8998
1
2
Valve spring compressor
90890-04019
Valve spring compressor YM-04019
Valve spring compressor attach-
ment 90890-04108
Valve spring compressor adapter
22 mm YM-04108
a 1
a

VALVES AND VALVE SPRINGS
6-26
c. After installing the valve guide, expand the hole in the valve guide with the valve guide
reamer “3” to obtain the proper valve-stem-
to-valve-guide clearance.
TIP
After replacing the valve guide, reface the valve
seat.
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3. Eliminate:• Carbon deposits(from the valve face and valve seat)
4. Check: • Valve facePitting/wear  Grind the valve face.
• Valve stem end Mushroom shape or diameter larger than
the body of the valve stem  Replace the
valve.
5. Measure: • Valve margin thickness “a”
Out of specification  Replace the valve. 6. Measure:
• Valve stem runout
Out of specification  Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
EAS2GC1252CHECKING THE VALVE SEATS
1. Eliminate: • Carbon deposits(from the valve face and valve seat)
2. Check: • Valve seatPitting/wear  Replace the cylinder head.
3. Measure: • Valve seat contact width “a”Out of specification  Replace the cylinder
head.
Valve guide remover & installer
set (ø5.5)
90890-04016
Valve guide remover (5.5 mm) YM-01122
Valve guide installer (5.5 mm) YM-04015
Valve guide reamer (5.5 mm) YM-01196
Valve margin thickness (intake) 1.20 mm (0.0472 in)
Valve margin thickness (exhaust) 0.85 mm (0.0335 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Valve seat contact width (ex-
haust) 0.90–1.10 mm (0.0354–0.0433 in)

VALVES AND VALVE SPRINGS
6-27
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a. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat contact width “c”.
TIP
Where the valve seat and the valve face are in
contact with each other, the blueing will have
been removed.
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4. Lap:
• Valve face
• Valve seat
ECA
NOTICE
This model uses titanium intake and ex-
haust valves.
Do not use the valves used for lapping the
valve seat. Always replace the valves used
for lapping with new ones.
TIP
• When replacing the cylinder head, replace also the valves with new ones without them.
• When replacing the valves or the valve guides, use new valves to lap the valve seats,
and then replace them with new valves.
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a. Apply a coarse lapping compound “a” to the
valve face.
ECA
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and the valve seat are evenly polished, then clean
off all of the lapping compound.
TIP
While turning the valve lapper, tap and lap the
valve seat.
e. Apply a fine lapping co mpound to the valve
face, and repeat the above steps.
f. After every lapping step, be sure to clean off all of the lapping compound from the valve
face and the valve seat.
c