2016 YAMAHA WR 450F water pump

IMPORTANT INFORMATION
1-7
EAS20180
IMPORTANT INFORMATION
EAS2GC1020PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before the jobs, completely remove mud, dust, and the like in order to prevent the en-
try of them into the inside during the jobs.
• Before cleaning with high-pressure water of washers, cover the following parts.
Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Hole under the water pump housing
2. Use proper special tools and equipment. See “SPECIAL TOOLS”.
3. During disassembly, check and measure the required parts, and make a record of them
so that you may refer to the record when in-
stalling them. Moreover, arrange gears, cyl-
inders, pistons, and other parts for each
section so as not to confuse or lose them. 4. During disassembly, clean each of the parts,
and store them in trays for each section.
5. Flammable. Keep servicing areas away from any source of fire.
6. During servicing, take special care not to re-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore,
rinse it out with water in good time.
EWA
WARNING
Coolant is potentially harmful and should
be handled with special care.
• If it enters your eyes, wash it away with wa-ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
EAS2GC1021REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
used for repair of the vehicle, including periodic
replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar ap-
pearances or because the quality may be
changed by aging.

ENGINE SPECIFICATIONS
2-2
EAS2GC1062
ENGINE SPECIFICATIONS
EngineEngine type Liquid cooled 4-stroke, DOHC
Displacement 449 cm
3
Number of cylinders Single cylinder
Bore  stroke 97.0  60.8 mm (3.82  2.39 in)
Compression ratio 12.5:1
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 7.5 L (2.0 US gal, 1.7 Imp.gal)
Fuel reserve amount 2.0 L (0.5 US gal, 0.4 Imp.gal)
Engine oilLubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-40, SAE 10W-50, SAE 15W-40, SAE 20W-40 or SAE 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard MA
Engine oil quantity
Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt)
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)
Oil filterOil filter type Paper
Bypass valve opening pressure 40.0–80.0 kPa (0.40–0.80 kgf/cm
2,
5.8–11.6 psi)
Oil pump Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clear ance 0.000–0.150 mm (0.0000–0.0059 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to -inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.17 mm (0.0067 in)
Cooling system
Radiator (including all routes) 1.03 L (1.09 US qt, 0.91 Imp.qt)
Radiator capacity 0.57 L (0.60 US qt, 0.50 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kg/cm
2,
15.6–19.9 psi)
Radiator core Width 112.6 mm (4.43 in)
Height 235.0 mm (9.25 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)Manufacturer/model NGK/CR8E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)

ENGINE SPECIFICATIONS
2-6
Fuel pumpPump type Electrical
Fuel injector
Model/quantity 1010/1
Resistance 12 
Throttle body
Type/quantity 30RA-A05U/1
ID mark 2GC1 00
Fuel line pressure (at idle) 300.0–390.0 kPa (3.00–3.90 kgf/cm
2, 43.5–
56.6 psi)
Throttle position sensor Resistance 6.30 k 
Output voltage (at idle) 0.48–0.52 V
Fuel injection sensor Crankshaft position sensor resistance 228–342 
Intake air pressure sensor output voltage 3.61–3.67 V at 101.3 kPa (3.61–3.67 V at 1.01 kgf/cm
2, 3.61–3.67 V at 14.7 psi)
Intake air temperature sensor resistance 290–390  at 80 °C (290–390  at 176 °F)
Coolant temperature sensor resistance 2512–2777  at 20 °C (2512–2777  at 68 °F)
210–220  at 100 °C (210–220  at 212 °F)
Idling condition
Engine idling speed 1900–2100 r/min
CO% 3.5–4.5 % (USA) (CAN)
Intake vacuum 32.8–36.8 kPa (246–276 mmHg, 9.7–10.9 inHg) (USA) (CAN)
Water temperature 70–90 °C (158–194 °F)
Oil temperature 70–80 °C (158–176 °F)
Throttle grip free play 3.0–6.0 mm (0.12–0.24 in)

TIGHTENING TORQUES
2-13
EAS2GC1066ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEM Thread
size Q’ty TIGHTENING TORQUES Remarks
Camshaft cap bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt (exhaust
pipe) M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head bolt M10 4See TIP.*1
Cylinder head bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage plug (cylinder head) M8 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf) Use a
lock
washer.
Balancer nut M10 1 45 Nm (4.5 m·kgf, 33 ft·lbf) Use a
lock
washer.
Timing chain guide stopper plate
(exhaust side) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator fan bolt M6 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Water pump housing cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screw M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage cover bolt (left crank-
case cover) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
E
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LUBRICATION POINTS AND LUBRICANT TYPES
2-21
EAS2GC1068
LUBRICATION POINTS AND LUBRICANT TYPES
EAS2GC1069ENGINE
Lubrication point Lubricant types
Oil seal lips
Bearing
O-ring
Camshaft cap bolt threads and contacting surface
Cylinder head bolt threads, seats, washers
Valve stems
Valve stem ends
Valve lifter outer surface
Camshaft lobe and journal
Valve lifter top surface
Crankshaft journal
Crankshaft big end thrust surfaces
Piston outer surface
Piston pin outer surface
Decompression system moving parts
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil passage gasket
Oil pump shaft
Kick gear and ratchet wheel
Kick shaft
Kick idle gear inner surface
Ratchet wheel and ratchet wheel guide contacting portion
Primary drive gear nut threads and contacting surface
Primary driven gear inner surface and end surface
Clutch push rod washer
Clutch push rod 1 outer surface
Clutch push rod 1 thrust surface
Clutch push rod 2 outer surface
Push lever shaft outer surface
Transmission gear inner surface (wheel and pinion) and collar
Transmission gears (shift fork groove)
Shift cam grooves
Shift fork and shift fork guide outer surface
Shift shaft and collar
Shift lever assembly moving parts
Damper assembly shaft, thrust surfaces, washers
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FRONT BRAKE
5-17
EAS2GC1168INTRODUCTIONEWA
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components unless absolutely necessary.
• If there is any problem with connections on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the
brake fluid, and clean it. After that, add a
suitable amount of brake fluid. Then, bleed
it after reassembly.
• Use only brake fluid for washing brake
components.
• Use new brake fluid for cleaning the brake components.
• Immediately wipe off the spilled brake fluid to avoid damage to painted surfaces or
plastic parts.
• Handle brake fluid with special care not to let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS2GC1169CHECKING THE FRONT BRAKE DISC
1. Remove: • Front wheel
Refer to “FRONT WHEEL” on page 5-4.
2. Check: • Front brake disc
Damage/galling  Replace.
3. Measure: • Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace. 4. Install:
• Front wheelRefer to “FRONT WHEEL” on page 5-4.
EAS2GC1170REMOVING THE FRONT BRAKE CALIPER
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:• Union bolt
• Copper washers
• Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid.
EAS2GC1171DISASSEMBLING THE FRONT BRAKE CAL-
IPER
1. Remove:• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seals “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening to force out the piston from the
brake caliper.
EWA
WARNING
• Cover the brake caliper piston with a rag. Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
Brake disc thickness limit 2.5 mm (0.10 in)
3
2
1

7
COOLING SYSTEM
RADIATOR....................................................................................................... 7-1
HANDLING NOTE ...................................................................................... 7-3
CHECKING THE RADIATOR ..................................................................... 7-3
WATER PUMP .................................................................................................. 7-4
REMOVING THE OIL SEAL ....................................................................... 7-5
CHECKING THE WATER PUMP ............................................................... 7-5
CHECKING THE BEARING ....................................................................... 7-5
INSTALLING THE OIL SEAL ..................................................................... 7-5
ASSEMBLING THE WATER PUMP........................................................... 7-5

WATER PUMP
7-4
EAS2GC1332
WATER PUMP
Removing the water pump
OrderPart name Q’tyRemarks
Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Right crankcase cover Refer to “CLUTCH” on page 6-41.
1 Water pump housing 1
2 Dowel pin 2
3Gasket 1
4Collar 1
5Pin 1
6 Impeller shaft assembly 1
7 Oil seal 1
8 Bearing 1
9 Oil seal 1
For installation, reverse the removal proce-
dure.
LS
LS
7
6
2 2
3
1
854
New
New
New
E
9
New
E
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.