2016 YAMAHA WR 450F tow

CONTROL FUNCTIONS
1-18
EAS2GC1029
CONTROL FUNCTIONS
EAS2GC1030INDICATOR LIGHTS AND WARNING
LIGHTS
Fuel level warning light “ ”
This warning light comes on when the fuel level
drops below approximately 1.6 L (0.42 US gal,
0.35 Imp.gal). When this occurs, refuel as soon
as possible.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the start switch is pushed, or if the warn-
ing light remains on, have a Yamaha dealer
check the electrical circuit.
Engine trouble warning light “ ”
This warning light comes on or flashes if a prob-
lem is detected in the electrical circuit monitor-
ing the engine. If this occurs, have a Yamaha
dealer check the vehicle.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the start switch is pushed, or if the warn-
ing light remains on, have a Yamaha dealer
check the electrical circuit.
EAS2GC1031ENGINE STOP SWITCH
The engine stop switch “1” is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
After the engine stops, the multi-function dis-
play will go off and the power supply to the ECU
(Electronic Control Unit) will be cut off if the en-
gine stop switch is pushed and held.
TIP
The multi-function display will go off after one
minute if the engine stop switch is not pushed.
EAS2GC1032START SWITCH
The start switch “1” is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.
EAS2GC1033CLUTCH LEVER
The clutch lever “1” is located on the left han-
dlebar. The clutch lever disengages or engag-
es the clutch.
Pull the clutch lever toward the handlebar to
disengage the clutch, and release the lever to
engage the clutch.
1. Engine trouble warning light “ ”
2. Fuel level warning light “ ”
12

CONTROL FUNCTIONS
1-19
EAS2GC1034SHIFT PEDAL
The shift pedal “1” has adopted a method of 1
down & 4 ups (press-down & kick-ups).
Press it down for N (neutral) to 1st, and kick it
up for 2nd to 5th.
Recommended shift points
The recommended shift points during accelera-
tion and deceleration are shown in the table be-
low.
EAS2GC1035KICKSTARTER LEVER
The kickstarter lever “1” is in the right of the
chassis.
To start the engine, pull out and push down the
kickstarter lever with your foot.
EAS2GC1036THROTTLE GRIP
The throttle grip “1” is located on the right han-
dlebar. The throttle grip accelerates or deceler-
ates the engine. For acceleration, turn the grip
toward you; for deceleration, turn it away from
you.
EAS2GC1037FRONT BRAKE LEVER
The front brake lever “1” is located on the right
handlebar. Pull it toward the handlebar to acti-
vate the front brake.
EAS2GC1038REAR BRAKE PEDAL
The rear brake pedal “1” is in the right of the
chassis. Press down on the brake pedal to ac-
tivate the rear brake.
Shift up points
1st  2nd: 20 km/h (12 mi/h)
2nd  3rd: 30 km/h (19 mi/h)
3rd  4th: 40 km/h (25 mi/h)
4th  5th: 50 km/h (31 mi/h)
Shift down points 5th  4th: 35 km/h (22 mi/h)
4th  3rd: 25 km/h (16 mi/h)
3rd  2nd: 25 km/h (16 mi/h)
2nd  1st: 25 km/h (16 mi/h)
1
1
1

CONTROL FUNCTIONS
1-20
EAS2GC1039SIDESTAND
This sidestand “1” is used to support only the
machine when standing or transporting it.
EWA
WARNING
• Never apply additional force to the sides-tand.
• Hold up the sidestand before starting out.
EAS2GC1040STARTER KNOB/IDLE SCREW
Starting a cold engine requires a larger amount
of intake air, which is supplied by the starter
knob/idle screw “1”.
Pulling the knob toward “a” turns ON the start-
er, resulting in a larger amount of intake air.
Pushing the knob toward “b” turns OFF the
starter.
EWA
WARNING
While handling the starter knob/idle screw,
take care not to burn yourself on exhaust
pipes.
EAS2GC1041FUEL TANK CAP
Fuel tank cap “1” is located under the fuel tank
cap cover “2”.
Remove the fuel tank cap cover to open the fuel
tank cap.
TIP
• To remove the fuel tank cap cover, insert fin-
gers under part “a”, and then use both hands
to lift it up towards the rear of the vehicle.
• Install the fuel tank cap cover after placing the
bands “3” all the way in under the seat.
1
a b1
1
23
a
2

CHASSIS
4-1
EAS2GC1136
CHASSIS
EAS2GC1137SELECTION OF THE SECONDARY REDUC-
TION RATIO (SPROCKET)
reduction ratio>
• It is generally said that the secondary gear ra-tio should be reduced for a longer straight por-
tion of a speed course and should be
increased for a course with many corners. Ac-
tually, however, as the speed depends on the
ground condition of the day of the race, be
sure to run through the circuit to set the ma-
chine suitable for the entire course.
• In actuality, it is very difficult to achieve set- tings suitable for the entire course and some
settings may be sacrificed. Thus, the settings
should be matched to the portion of the
course that has the greatest effect on the race
result. In such a case, run through the entire
course while making notes of lap times to find
the best balance; then, determine the second-
ary reduction ratio.
• If a course has a long straight portion where a machine can run at maximum speed, the ma-
chine is generally set such that it can develop
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en-
gine over-revving.
TIP
Riding technique varies from rider to rider and
the performance of a machine also vary from
machine to machine. Therefore, do not imitate
other rider’s settings from the beginning but
choose your own setting according to the level
of your riding technique.
EAS2GC1138DRIVE AND REAR WHEEL SPROCKETS
SETTING PARTS
EAS2GC1139TIRE PRESSURE
Tire pressure should be adjusted to suit the
road surface condition of the circuit.
• Under a rainy, a muddy, a sandy, or a slippery condition, the tire pressure should be lower
for a larger area of contact with the road sur-
face.
Secondary reduction ratio = Number of
rear wheel sprocket teeth/Number of
drive sprocket teeth
Secondary reduction ratio 3.846 (50/13)
Part name Type Part number
Drive sprocket “1”
(STD) 13T 9383E-13233
Rear wheel
sprocket “2”
48T 5GS-25448-50
(STD) 50T 5TJ-25450-80 52T 5TJ-25452-80
Standard tire pressure 100 kPa (1.00 kgf/cm
2,15 psi)
Extent of adjustment 60–80 kPa (0.60–0.80 kgf/cm
2, 9–
12 psi)

CHASSIS
4-6
EAS2GC1148SUSPENSION SETTING (FRONT FORK)
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absor ber sunken length to the standard figure 90–100 mm
(3.5–3.9 in).
Symptom Section
CheckAdjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff over entire
range Compression
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil amount Decrease oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with soft spring.
Unsmooth
movement over
entire range Outer tube
Inner tube
Check for any bends, dents,
other noticeable scars, etc. If
any, replace affected parts.
Slide metal Replace with a new one for ex- tended use.
Piston metal Replace with a new one for ex- tended use.
Lower bracket
tightening
torque Retighten to specified torque.
Poor initial
movement Rebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil seals Apply grease in oil seal wall.
Soft over entire
range, bottom-
ing out Compression
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Oil amount Increase oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with stiff spring.
Stiff toward
stroke end Oil amountDecrease oil amount by about
5 cm
3 (0.2 US oz, 0.2 Imp.oz).
Soft toward
stroke end, bot-
toming out Oil amountIncrease oil amount by about 5
cm
3 (0.2 US oz, 0.2 Imp.oz).
Stiff initial
movement Compression
damping forceTurn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.

FRONT BRAKE
5-22
TIP
Turn the handlebar toward right and left to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Adjust if necessary.
3. Pour brake fluid to the brake master cylinder reservoir up to the specified level.
EWA
WARNING
• Use only the designated brake fluid. Other brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could
cause vapor lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• Brake systemRefer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
5. Check: • Brake fluid level
The minimum level mark “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30. 6. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” on page 3-26.
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
Specified brake fluid
DOT 4
a

ENGINE REMOVAL
6-7
EAS2GC1230REMOVING THE ENGINE
1. Remove:• Pivot shaft “1”
TIP
If the pivot shaft is pulled all the way out, the
swingarm will come loose. If possible, insert a
shaft of similar diameter into the other side of
the swingarm to support it.
2. Remove:• Engine “1”
From the right side.
TIP
• Make sure that the couplers, the hoses, and the cables are disconnected.
• Lift up the engine, and remove this from its
lower part toward the right of the chassis.
EAS2GC1231CLEANING THE SPARK ARRESTEREWA
WARNING
• Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester.
• Do not start the engine when cleaning the
exhaust system.
1. Remove: • Muffler cap screws “1”
2. Remove: • Spark arrester bolts “1”
3. Remove: • Tail pipe “1”
• Tail pipe gasket “2”
• Spark arrester “3”Pull the spark arrester out of the muffler.
• Spark arrester gasket “4”
4. Clean: • Spark arresterTap the spark arrester lightly, then use a
wire brush to remove any carbon deposits.
1

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