YAMAHA WR 450F 2016 Owners Manual

CLUTCH
6-44
EAS2GC1266REMOVING THE CLUTCH
1. Remove:• Clutch boss nut “1”
• Conical washer “2”
• Clutch boss “3”
TIP
While holding the clutch boss with the clutch
holder “4”, loosen the clutch boss nut.
EAS2GC1267CHECKING THE FRICTION PLATES
1. Check:• Friction plate
Damage/wear  Replace the friction plates
as a set.
2. Measure:
• Friction plate thicknessOut of specification  Replace the friction
plates as a set.
TIP
Measure it at four points on the friction plate.
EAS2GC1268
CHECKING THE CLUTCH PLATES
1. Check: • Clutch plate
Damage  Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage(with a surface plate and thickness gauge
“1”)
Out of specification  Replace the clutch
plates as a set.
EAS2GC1269CHECKING THE CLUTCH SPRINGS
1. Check: • Clutch springDamage  Replace the clutch springs as a
set.
2. Measure: • Clutch spring free lengthOut of specification  Replace the clutch
springs as a set.
Universal clutch holder
90890-04086
Universal clutch holder YM-91042
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.85 mm (0.112 in)
3 4
12
Warpage limit
0.10 mm (0.004 in)
Clutch spring free length 50.00 mm (1.97 in)
Limit 47.50 mm (1.87 in)

CLUTCH
6-45
EAS2GC1270CHECKING THE CLUTCH HOUSING
1. Check:• Clutch housing dogs “a”Damage/pitting/wear  Deburr the clutch
housing dogs or replace the clutch housing.
TIP
Pitting on the clutch ho using dogs will cause er-
ratic clutch operation.
EAS2GC1271CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear  Replace the clutch
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS2GC1272CHECKING THE PRESSURE PLATE
1. Check: • Pressure plateCrack/damage  Replace.
EAS2GC1273CHECKING THE PUSH LEVER SHAFT
1. Check:
• Push lever shaftWear/damage  Replace.
EAS2GC1274CHECKING THE CLUTCH PUSH RODS
1. Check:
• Push rod 1 “1”
• Bearing “2”
• Washer “3”
• Push rod 2 “4”
•Ball “5”
Cracks/damage/wear  Replace.
2. Measure: • Push rod 2 bending limit
Out of specification  Replace.
EAS2GC1275CHECKING THE PRIMARY DRIVE GEAR
1. Check:
• Primary drive gearDamage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Re-
place the primary drive and primary driven
gears as a set.
2. Check: • Primary-drive-gear-to-primary-driven-gear free play
Free play exists  Replace the primary
drive and primary driven gears as a set.
a
Push rod bending limit 0.10 mm (0.004 in)

CLUTCH
6-46
EAS2GC1276CHECKING THE PRIMARY DRIVEN GEAR
1. Check:• Primary driven gearDamage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Re-
place the primary drive and primary driven
gears as a set.
EAS2GC1277INSTALLING THE OIL SEAL
1. Install: • Oil seal “1”
• Washer “2”
• Circlip “3”
TIP
• Apply the lithium-soap-based grease on the
oil seal lip.
• Install the oil seal in parallel with its manufac-
ture's marks or numbers facing inward.
EAS2GC1278INSTALLING THE RIGHT CRANKCASE
COVER
1. Install: • Dowel pin “1”
• O-rings “2”
• Collar “3”
• Gasket “4”
TIP
Apply the lithium-soap-based grease on the O-
ring.
2. Install:
• Right crankcase cover “1” • Right crankcase cover bolt “2”
TIP
• Apply the engine oil on the impeller shaft end.
• When installing the crankcase cover onto the
crankcase, make sure that the impeller shaft
end “3” aligns with the balancer end slot “4”.
• Tighten the right crankcase cover bolts in
stages and in a crisscross pattern.
EAS2GC1279INSTALLING THE CLUTCH
1. Install:
• Push lever shaft “1”
TIP
• Apply the lithium-soap-based grease on the oil seal lip.
• Before installation, apply the engine oil to the
push lever shaft sliding surface.
New
New
3
2
1
LS
New
New
1
1
4
2
New
New
3
LS
Right crankcase cover bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
1 2
1

CLUTCH
6-47
2. Install:• Primary driven gear “1”
• Thrust washer “2”
• Clutch boss “3”
TIP
Apply the engine oil on the primary driven gear
inner circumference.
3. Install:• Conical washer “1”
• Clutch boss nut “2”
ECA1DX1020
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is
fastened together.
TIP
• Install the conical washer with its convex sur-face “a” outward.
• Apply engine oil to the threads and contact surface of the clutch boss nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Use the clutch holding tool “3” to hold the
clutch boss. 4. Install:
• Friction plate 1 “1”
• Clutch plate 2 “2”
• Cushion spring “3”
• Friction plate 2 “4”
• Clutch plate 1 “5”
TIP
• Install the clutch plates and friction plates al-
ternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• From the clutch boss side, install the friction
plates in order: friction plate 1  2, friction
plate 2 (identification color: purple)  5, and
friction plate 1  1.
• From the clutch boss side, the clutch plate in order: clutch plate 2 (thickness: 1.6 mm)  3,
and clutch plate 1 (thickness: 2.0 mm)  4.
• Apply the engine oil on the friction plates and
clutch plates.
Clutch boss nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
Universal clutch holder 90890-04086
Universal clutch holder YM-91042
New
T R..
a. Identification color
a2
3
21
1
314
225
1 4
5
a
4 53
4
2
1

CLUTCH
6-48
5. Install:• Bearing “1”
• Washer “2”
• Circlip “3” To push rod 1 “4”.
TIP
Apply the engine oil on the bearing and washer.
6. Install:• Push rod 2 “1”
•Ball “2”
• Push rod 1 “3”
TIP
Apply the engine oil on the push rod 1, 2 and
ball.
7. Install:
• Pressure plate “1” 8. Install:
• Clutch spring
• Clutch spring bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
9. Install:• O-ring “1”
TIP
Apply the lithium-soap-based grease to the O-
ring.
10.Install:• Clutch cover “1”
• Clutch cover bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
NewClutch spring bolt10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
New
T R..

CLUTCH
6-49
EAS2GC1280INSTALLING THE KICKSTARTER LEVER
1. Install:• Kickstarter lever “1”
• Washer
• Bolt (kickstarter lever)
TIP
Install so that there is a clearance “a” of 5 mm
(0.2 in) or more between the kickstarter lever
and the frame and that the kickstarter lever
does not contact the right crankcase cover
when it is pulled. Bolt (kickstarter lever)
33 Nm (3.3 m·kgf, 24 ft·lbf)
LOCTITE®
1
T R..
1
a

KICKSTATER
6-50
EAS2GC1281
KICKSTATER
Removing the kick shaft
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
1 Kick idle gear 1
2 Kick shaft assembly 1
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick shaft 1
For installation, reverse the removal proce-
dure.

KICKSTATER
6-51
EAS2GC1282REMOVING THE KICK SHAFT ASSEMBLY
1. Remove:• Kick shaft assembly “1”
TIP
Unhook the torsion spring “2” from the hole “a”
in the crankcase.
EAS2GC1283CHECKING THE KICK SHAFT AND RATCH-
ET WHEEL
1. Check:• Ratchet wheel “1” smooth movementUnsmooth movement  Replace.
• Kick shaft “2” Wear/damage  Replace the kick shaft as-
sembly.
• Spring “3” Broken  Replace.
EAS2GC1284CHECKING THE KICK GEAR, KICK IDLE
GEAR AND RATCHET WHEEL
1. Check:
• Kick gear “1”
Wear/damage  Replace the kick shaft as-
sembly.
• Kick idle gear “2”
• Ratchet wheel “3”
• Gear teeth “a”
• Ratchet teeth “b”
Wear/damage  Replace.
EAS2GC1285INSTALLING THE KICK SHAFT ASSEMBLY
1. Install:
• Kick gear “1”
• Washer “2”
• Circlip “3”
• Ratchet wheel “4”
• Spring “5”
• Washer “6”
• Circlip “7”
(to the kick shaft “8”)
TIP
• Apply molybdenum disulfide oil to the inner circumferences of the kick gear and ratchet
wheel.
• Align the punch mark “a” on the ratchet wheel
with the punch mark “b” on the kick shaft.
2. Install: • Torsion spring “1”
(to the kick shaft “2”)
TIP
Make sure the stopper “a” of the torsion spring
fits into the hole “b” on the kick shaft.
3 1
2
a
b 3
12
New
New

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

SHIFT SHAFT
6-53
EAS2GC1287
SHIFT SHAFT
Removing the shift shaft and stopper lever
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
1 Shift pedal 1
2 Shift shaft 1
3 Oil seal 1
4Collar 1
5 Shift shaft spring 1
6Roller 1
7 Shift guide 1
8 Shift lever assembly 1
9 Shift lever 1
10 Pawl 2
11 Pawl pin 2
12 Spring 2
13 Stopper lever 1
14 Stopper lever spring 1
15 Segment 1
For installation, reverse the removal proce-
dure.
LS
1
3
13
15
14
LT
6
10
11
12
11 8
12 10
4
2 5
LT
7
LT
E
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
30 Nm (3.0 m kgf, 22 ftT.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
Ibf)
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.