2016 YAMAHA WR 450F warning light

1
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS............................................................ 1-1
DESCRIPTION .................................................................................................. 1-4
IDENTIFICATION ............................................................................................. 1-5
VEHICLE IDENTIFICATION NUMBER ...................................................... 1-5
ENGINE SERIAL NUMBER ....................................................................... 1-5
VEHICLE EMISSION CONTROL INFORMATION LABEL......................... 1-5
INCLUDED PARTS .......................................................................................... 1-6
SPARK PLUG WRENCH ........................................................................... 1-6
NIPPLE WRENCH...................................................................................... 1-6
HANDLEBAR PROTECTOR .. .................................................................... 1-6
FUEL HOSE JOINT COVER ...................................................................... 1-6
COUPLER FOR CONNECTING OPTIONAL PART................................... 1-6
IMPORTANT INFORMATION .......................................................................... 1-7
PREPARATION FOR REMOVAL A ND DISASSEMBLY............................ 1-7
REPLACEMENT PARTS............................................................................ 1-7
GASKETS, OIL SEALS AND O-RINGS ..................................................... 1-8
LOCK WASHERS/PLATES AND COTTER PINS ...................................... 1-8
BEARINGS AND OIL SEALS ..................................................................... 1-8
CIRCLIPS ................................................................................................... 1-8
BASIC SERVICE INFORMATION .................................................................... 1-9
ELECTRICAL SYSTEM.......... .................................................................... 1-9
SPECIAL TOOLS ........................................................................................... 1-13
CONTROL FUNCTIONS ................................................................................ 1-18
INDICATOR LIGHTS AND WARNING LIGHTS ....................................... 1-18
ENGINE STOP SWITCH .......................................................................... 1-18
START SWITCH....................................................................................... 1-18
CLUTCH LEVER ................................................................................... ... 1-18
SHIFT PEDAL .......................................................................................... 1-19
KICKSTARTER LEVER.......... .................................................................. 1-19
THROTTLE GRIP ..................................................................................... 1-19
FRONT BRAKE LEVER ........................................................................... 1-19
REAR BRAKE PEDAL.............................................................................. 1-19
SIDESTAND ............................................................................................. 1-20
STARTER KNOB/IDLE SCREW .............................................................. 1-20
FUEL TANK CAP ..................................................................................... 1-20

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

STARTING AND BREAK-IN
1-29
ECA
NOTICE
If the starter motor will not turn when the
start switch is pushed, stop pushing it im-
mediately in order to avoid placing extra
load on the starter motor, and start the en-
gine by using the kickstarter.
TIP
If the engine fails to start, push the engine stop
switch and give the kickstarter 10 to 20 slow
kicks at full throttle in order to clear the engine
of the rich air-fuel mixture retained in it.
4. When the engine starts running, warm this up one or two minutes at a steady speed (of
3000 to 5000 r/min), and then return the
starter knob/idle screw to its original posi-
tion.
EWA
WARNING
Since exhaust gas contains harmful ingre-
dients, do not start or warm it up at an ill-
ventilated place or a closed narrow place.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
5. To stop the engine, push the engine stop switch “1”.
TIP
Continue pushing the engine stop switch till the
engine comes to a full stop. Starting with the kickstarter
When using the kickstarter to start the engine,
follow the procedures as described below.
1. Fold out the kickstarter lever, push it down
lightly with your foot until resistance is felt.
2. With the throttle fully closed,push the kick- starter down lightly until the gears engage,
and then push it down smoothly but forceful-
ly.
EWA
WARNING
Do not open the throttle while kicking the
kickstarter lever. Otherwise, the kickstarter
lever may kick back.
TIP
If the engine fails to start, push the engine stop
switch and give the kickstarter 10 to 20 slow
kicks at full throttle in order to clear the engine
of the rich air-fuel mixture retained in it.

MOTORCYCLE CARE AND STORAGE
1-35
2. Apply a corrosion protection spray on all metal, including chrome- and nickel-plated,
surfaces to prevent corrosion.
After cleaning
1. Dry the motorcycle with a chamois or an ab- sorbing cloth.
2. Immediately dry the drive chain and lubri- cate it to prevent it from rusting.
3. Use a chrome polish to shine chrome, alumi-
num and stainless- st eel parts, including the
exhaust system. (Even the thermally in-
duced discoloring of stainless- steel exhaust
systems can be removed through polishing.)
4. To prevent corrosion, it is recommended to apply a corrosion protection spray on all
metal, including chrome- and nickel-plated,
surfaces.
5. Use spray oil as a universal cleaner to re- move any remaining dirt.
6. Touch up minor paint damage caused by stones, etc.
7. Wax all painted surfaces.
8. Let the motorcycle dry completely before
storing or covering it.
EWA
WARNING
Contaminants on the brakes or tires can
cause loss of control.
• Make sure that there is no oil or wax on the brakes or tires.
• If necessary, clean the brake discs and
brake linings with a regular brake disc
cleaner or acetone, and wash the tires with
warm water and a mild detergent. Before
riding at higher speeds, test the motorcy-
cle’s braking performance and cornering
behavior.
ECA
NOTICE
• Apply spray oil and wax sparingly and make sure to wipe off any excess.
• Never apply oil or wax to any rubber and
plastic parts, but treat them with a suitable
care product.
• Avoid using abrasive polishing com-
pounds as they will wear away the paint.
TIP
• Consult a Yamaha dealer for advice on what products to use.
• Washing, rainy weather or humid climates can cause the headlight lens to fog. Turning
the headlight on for a short period of time will
help remove the moisture from the lens.
EAS2GC1060STORAGE
Short-term
Always store your motorcycle in a cool, dry
place and, if necessary, protect it against dust
with a porous cover. Be sure the engine and the
exhaust system are cool before covering the
motorcycle.
ECA
NOTICE
• Storing the motorcycle in a poorly ventilat-ed room or covering it with a tarp, while it
is still wet, will allow water and humidity to
seep in and cause rust.
• To prevent corrosion, avoid damp cellars,
stables (because of the presence of am-
monia) and areas where strong chemicals
are stored.
Long-term
Before storing your motorcycle for several
months:
1. Follow all the instructions in the “Care” sec- tion of this chapter.
2. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel tank from rust-
ing and the fuel from deteriorating.
3. Perform the following steps to protect the
cylinder, piston rings, etc. from corrosion.
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a. Remove the spark plug cap and spark plug.
b. Pour a teaspoonful of engine oil into the spark plug bore.
c. Install the spark plug cap onto the spark plug, and then place the spark plug on the
cylinder head so that the electrodes are
grounded. (This will limit sparking during the
next step.)
d. Turn the engine over several times with the
starter. (This will coat the cylinder wall with
oil.)

ELECTRICAL SPECIFICATIONS
2-10
EAS2GC1064
ELECTRICAL SPECIFICATIONS
VoltageSystem voltage 12 V
Ignition systemIgnition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min
Engine control unitModel/manufacturer 2GC0/YAMAHA (USA) (CAN) 2GC1/YAMAHA (EUR) (AUS) (NZL) (ZAF)
Ignition coilMinimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k 
Spark plug cap
Resistance 7.50–12.50 k 
Lean angle sensor output voltage
Operating angle 45 °
Output voltage up to operating angle 3.7–4.4 V
Output voltage over operating angle 0.4–1.4 V
AC magneto
Standard output 14.0 V, 160 W at 5000 r/min
Stator coil resistance 0.528–0.792  (W–W)
Rectifier/regulator
Regulator type Three-phase
No load regulated voltage 14.1–14.9 V
Rectifier capacity (DC) 35.0 A
BatteryModel YTZ7S (F)
Voltage, capacity 12 V, 6.0 Ah (10HR)
Specific gravity 1.31
Manufacturer GS YUASA
Ten hour rate charging current 0.60 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage  quantity
Headlight HS1, 35.0 W/35.0 W  1 (Hi)
Tail/brake light LED
Meter lighting EL (Electroluminescent)
Indicator light
Fuel level warning light 12 V, 1.7 W  1
Engine trouble warning light 12 V, 1.7 W  1
Electric starting system
System type Constant mesh

ENGINE
3-18
c. Replace the O-ring “2”.
d. Install the oil strainer.
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6. Install:•Gasket
• Drain bolt
7. Pour the specified amount of engine oil into the oil filler cap hole.
8. Install: • Oil filler cap
9. Check: • Oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-16. 10.Check:
• Engine oil pressure
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a. Slightly loosen the oil pressure check bolt “1”.
EWA
WARNING
When the engine is started with the check
bolt removed, oil will spout; therefore, al-
ways loosen it before the checkup.
b. Start the engine and keep it idling until oil starts to seep from the oil pressure check
bolt.
EWA
WARNING
Always keep the engine idling speed during
the checkup without increasing the engine
speed.
ECA
NOTICE
If no engine oil seeps out after one minute,
immediately turn the engine off so it will not
seize.
c. If no engine oil seeps out, check the engine oil for leaks, and t he engine oil passage and
the oil pump for damage.
d. Check the oil pressure again.
e. Tighten the oil pressure check bolt.
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Oil strainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drain bolt 20 Nm (2.0 m·kgf, 14 ft·lbf)
Engine oil quantity Oil change 0.67 L (0.71 US qt, 0.59 Imp.qt)
With oil filter removal 0.69 L (0.73 US qt, 0.61 Imp.qt)
Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt)
1
2New
T R..
New
T R..
Oil pressure check bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
T R..

ELECTRICAL SYSTEM
3-41
2. Attach:• Timing light “1”
• Digital tachometer “2”To the high tension code “3”.
3. Adjust: • Engine idling speedRefer to “ADJUSTING THE ENGINE
IDLING SPEED” on page 3-19.
4. Check: • Ignition timingCheck whether the alignment mark “a” on
the left crankcase cover is within the firing
range “b” on the rotor.
Incorrect firing range  Check rotor and
Crankshaft position sensor.
5. Install: • Timing mark accessing screwEAS2GC1133CHECKING AND CHARGING THE BATTERY
Refer to “CHECKING AND CHARGING THE
BATTERY” on page 9-69.
EAS2GC1134REPLACING THE HEADLIGHT BULBEWA
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
1. Remove:• Headlight unit bolt “1”
TIP
After you have removed the headlight unit
bolts, lift and remove the headlight unit.
2. Remove:
• Headlight coupler “1”
• Bulb cover “2”
3. Remove: • Headlight bulb “1”
Timing light
90890-03141
Timing light YU-03141
Digital tachometer 90890-06760
Digital tachometer YU-39951-B
Timing mark accessing screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
2
1
3
ba
T R..
11
1
2
1

HANDLEBAR
5-36
NOTICE
• First, tighten the bolts on the front side of the upper handlebar holder, and then on
the rear side.
• Turn the handlebar all the way to the left and right. If there is any contact with the
fuel tank, adjust the handlebar position.
3. Tighten:• Lower handlebar holder nut
4. Install: • Handlebar grip “1”
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a. Slightly coat the handlebar left end with a rubber adhesive.
b. Install the handlebar grip on the handlebar by pressing the grip from the left side.
c. Wipe off any excess adhesive with a clean cloth.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Install the handlebar grip to the handlebar so
that the line “a” between the two arrow marks
faces straight upward.
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2
1
1
a
3
4
Lower handlebar holder nut40 Nm (4.0 m·kgf, 29 ft·lbf)
T R..