YAMAHA WR 450F 2016 Owners Manual

CABLE ROUTING DIAGRAM
2-40
1. Battery negative lead
2. Fuel hose
3. Fuel pump coupler
4. Fuel pump lead
5. Resistor
6. Resistor coupler
7. Battery positive lead
8. Lean angle sensor
9. Starter motor lead
10. Radiator fan motor relay (blue tape)
11. Main relay (red tape)
12. Wire harness
13. Ground lead coupler
14. Starter relay coupler
15. Starter relay
16. Cross member
17. Diode
18. Taillight lead
19. Clamp
20. Fuel tank
21. Damper
22. Rear frame
23. Side cover 6
24. Plastic locking tie
A. After connecting the fuel pump coupler, attach the coupler cover.
B. Pass the fuel hose to the front of the battery.
C. Route the resistor lead to the outside of the leads.
D. Connect the battery positive lead to the starter re- lay terminal (in the left side of the vehicle).
E. Insert the protruding end of the wire harness into
the battery bracket hole and holder plate hole.
F. After connecting the negative lead coupler, place it on the right side of the battery.
G. Route the diode under the cross member and place it on top of the rear fender.
H. Secure the two ends of the taillight coupler with the starter motor lead.
I. Route the taillight lead so that it does not slack at
the rear of the vehicle.
J. Clamp the taillight lead and insert the clip into the rear fender. Clamp it so that the lock faces in-
ward, and then cut off the excess end.
K. Lower end of the rear frame
L. Clamp it so that the lock of the plastic locking tie
faces downward, insert the end into the rear
frame and side cover 6, and then cut off the ex-
cess end. After cutting off the excess end, make
sure that the plastic locki ng tie does not protrude
from the lower end of the rear frame.
M. Clamp it so that the lock of the plastic locking tie
faces downward, and then pass the end between
the fuel hose and rear frame.
N. Clamp the wire harness at the position of the white tape.
O. Route the battery positive lead under the cross member.
P. After connecting the battery positive lead in the direction indicated in the illustration, put the cover
on.

CABLE ROUTING DIAGRAM
2-41

CABLE ROUTING DIAGRAM
2-42
1. Clutch switch lead
2. Engine stop switch lead
3. Clutch cable
4. Brake hose guide
5. Headlight lead
6. Speed sensor lead
7. Indicator light coupler
8. Meter assembly optional switch coupler
9. Meter assembly coupler
10. Speed sensor coupler
11. Start switch lead
12. Plastic band
13. Throttle cable
14. Front brake hose
A. Route the throttle cable, clutch cable, clutch switch lead, engine stop switch lead and start
switch lead between the cable guide of the meter
bracket and handle crown. The cables and leads
may be routed in any order.
B. Clamp the wire harness, clutch switch lead and start switch lead to the meter bracket. The clamp
shall be located at a pos ition where there is no
slack with the handle turned fully to the left.
C. Connect the headlight lead to the headlight.
D. Clamp the start switch lead to the handlebar by the plastic band.
E. Clamp the engine stop switch lead and clutch switch lead to the handlebar by the plastic band.
F. 40°±10°
G. Vertical direction
H. Pass the engine stop switch lead under the han- dlebar.

CABLE ROUTING DIAGRAM
2-43

CABLE ROUTING DIAGRAM
2-44
1. Brake master cylinder
2. Brake hose holder
3. Brake hoses
A. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact
with the projection on the brake caliper.
B. Pass the brake hose into the brake hose holders.
C. If the brake hose interfer es with the rear shock
absorber, correct its twist.
D. While installing the brake hose, direct a bend in its pipe portion as shown, and bring it into contact
with the projection on the brake master cylinder.

CABLE ROUTING DIAGRAM
2-45

3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................. 3-1
INTRODUCTION ........................................................................................ 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ....................... .......................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 3-2
MAINTENANCE INTERVALS FOR COMPETITION USE ......................... 3-4
PRE-OPERATION INSPECTION AND MAINTENANCE ................................. 3-9
GENERAL INSPECTION AND MAINTENANCE........................................ 3-9
ENGINE .......................................................................................................... 3-10
CHECKING THE COOLANT LEVEL ........................................................ 3-10
CHECKING THE COOLING SYSTEM ..................................................... 3-10
CHANGING THE COOLANT.................................................................... 3-10
CHECKING THE RADIATOR CAP .......................................................... 3-11
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ....... 3-11
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-12
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-13
LUBRICATING THE THROTTLE CABLE ................................................ 3-14
CLEANING THE AIR FILTER ELEMENT................................................. 3-14
CHECKING THE THROTTLE BODY JOINT ............................................ 3-15
CHECKING THE BREATHER HOSES .................................................... 3-15
CHECKING THE EXHAUST SYSTEM............................. ........................ 3-15
CHECKING THE FUEL LINE ................................................................... 3-16
CHECKING THE ENGINE OIL LEVEL............................. ........................ 3-16
CHANGING THE ENGINE OIL ................................................................ 3-17
ADJUSTING THE ENGINE IDLING SPEED ......... ................................... 3-19
ADJUSTING THE VALVE CLEARANCE ................................................. 3-20
CLEANING THE SPARK ARRESTER ..................................................... 3-24
CHASSIS ........................................................................................................ 3-25
BLEEDING THE BRAKE SYST EM .......................................................... 3-25
CHECKING THE BRAKE HOSE .............................................................. 3-26
ADJUSTING THE FRONT BRAKE .......................................................... 3-26
ADJUSTING THE REAR BRAKE ............................................................. 3-27
CHECKING THE FRONT BR AKE PADS ................................................. 3-27
CHECKING THE REAR BRAKE PADS ........................... ........................ 3-29
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-30
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-30
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-31
CHECKING THE FRONT FORK LEGS ................................................... 3-31
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-32
CLEANING THE FRONT FORK OI L SEAL AND DUST SEAL ................ 3-32
AIR BLEEDING FROM FRONT FORK .................................................... 3-32
ADJUSTING THE FRONT FORK LEGS .................................................. 3-33
CHECKING THE SWINGARM OPERATION ........................................... 3-34
CHECKING THE REAR SUSPENSION ................................................... 3-34

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-34
CHECKING THE TIRES ........................................................................... 3-36
CHECKING AND TIGHTENING THE SPOKES ....................................... 3-36
CHECKING THE WHEELS ...................................................................... 3-37
CHECKING THE WHEEL BEAR INGS ..................................................... 3-37
CHECKING AND ADJUSTING THE STEERING HEAD .......................... 3-37
CHECKING AND LUBRICATING THE CABLES ..................................... 3-38
LUBRICATING THE LEVERS .................................................................. 3-38
LUBRICATING THE PEDAL .................................................................... 3-38
LUBRICATING THE DRIVE CHAIN ......................................................... 3-39
LUBRICATING THE SIDESTAND............................................................ 3-39
CHECKING THE CHASSIS FASTENERS ............................................... 3-39
ELECTRICAL SYSTEM .................................................................................. 3-40
CHECKING THE SPARK PL UG .............................................................. 3-40
CHECKING THE IGNITION TIMING ........................................................ 3-40
CHECKING AND CHARGING THE BATTERY ........................................ 3-41
REPLACING THE HEADLIGHT BULB..................................................... 3-41

PERIODIC MAINTENANCE
3-1
EAS2GC1074
PERIODIC MAINTENANCE
EAS2GC1075INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly ov erhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS2GC1076PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP
• From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER READ-
INGS
600 mi (1000
km) or 1 month 1800 mi
(3000
km) or 3 months 3000 mi
(5000
km) or 6 months
1* Fuel line • Check fuel hoses for cracks or dam-
age.
• Replace if necessary. 
2Spark plug
• Check condition.
• Adjust gap and clean. 
3*Valve clear-
ance • Check and adjust valve clearance
when engine is cold. 
4*Air filter ele-
ment • Clean with solvent and apply Yamaha
foam air filter oil or other quality foam
air filter oil.
• Replace if necessary. 
5*
Breather
system • Check ventilation hose for cracks or
damage and drain any deposits. 
6*Fuel injec-
tion • Adjust engine idling speed.

7Exhaust sys-
tem• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.

8Engine oil
• Change (warm engine before drain-
ing). 
9Engine oil fil-
ter element•Replace.

10Engine oil
strainer• Clean.


PERIODIC MAINTENANCE
3-2
EAS2GC1077GENERAL MAINTENANCE AND LUBRICATION CHARTNO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER READ-
INGS
600 mi (1000
km) or 1 month 1800 mi
(3000
km) or 3 months 3000 mi
(5000
km) or 6 months
1Clutch • Check operation.
• Adjust or replace cable. 
2*Cooling sys-
tem • Check hoses for cracks of damage.
• Replace if necessary.

• Replace with ethylene glycol anti- freeze coolant every 1 year. Every 1 year
3*Spark arrest-
er • Clean.

4*Front brake • Check operation, fluid level, and for flu-
id leakage.
• Replace brake pads if necessary. 
• Replace brake fluid every 1 year. Every 1 year
5* Rear brake • Check operation, fluid level, and for flu-
id leakage.
• Replace brake pads if necessary. 
• Replace brake fluid every 1 year. Every 1 year
6* Brake hoses • Check for cracks or damage.

• Replace. Every 4 years
7*Wheels • Check runout, spoke tightness and for
damage.
• Tighten spokes if necessary. 
8*
Tires • Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary. 
9*
Wheel bear-
ings • Check bearings for smooth operation.
• Replace if necessary.

10*Swingarm
pivot bear-
ings • Check bearing assemblies for loose-
ness.
• Moderately repack with lithium-soap- based grease. 
11Drive chain• Check chain slack/alignment and con-
dition.
• Adjust and lubricate chain with a spe- cial O-ring chain lubricant thoroughly. Every ride
12*
Steering
bearings • Check bearing assemblies for loose-
ness.
• Moderately repack with lithium-soap- based grease every 1200 mi (2000
km) or 12 months (whichever comes
first). 