YAMAHA WR 450F 2016 Owners Manual

SHIFT SHAFT
6-54
EAS2GC1288REMOVING THE SHIFT GUIDE AND SHIFT
LEVER ASSEMBLY
1. Remove:• Bolt (shift guide)
• Shift guide “1”
• Shift lever assembly “2”
TIP
Make sure that the shift lever assembly is re-
moved together with the shift guide.
EAS2GC1289REMOVING THE SEGMENT
1. Remove:
• Bolt (segment) “1”
• Segment “2”
TIP
Turn the segment counterclockwise until it
stops and loosen the bolt.
ECA
NOTICE
If the segment gets an impact, the stopper
lever may be damaged. Take care not to
give an impact to it when removing the bolt.
EAS2GC1290CHECKING THE SHIFT SHAFT
1. Check:• Shift shaft “1”
Bends/damage/wear  Replace.
• Shift shaft spring “2” Damage/wear  Replace.
EAS2GC1291CHECKING THE SHIFT GUIDE AND SHIFT
LEVER ASSEMBLY
1. Check:
• Shift guide “1”
• Shift lever “2”
•Pawl “3”
• Pawl pin “4”
• Spring “5”Wear/damage  Replace.
EAS2GC1292CHECKING THE STOPPER LEVER
1. Check:
• Stopper lever “1”Wear/damage  Replace.
• Torsion spring “2”
Broken  Replace.
1
2
1
2 3
4
5
12

SHIFT SHAFT
6-55
EAS2GC1293INSTALLING THE STOPPER LEVER
1. Install:• Torsion spring “1”
• Collar “2”
• Stopper lever “3”
• Bolt (stopper lever) “4”
EAS2GC1294INSTALLING THE SEGMENT
1. Install:• Segment “1”
• Segment bolt
TIP
• Align the notch “a” on the segment with the pin “b” on the shift cam.
• With the stopper lever pushed down, install
the segment.
ECA
NOTICE
If the segment gets an impact, the stopper
lever may be damaged. Take care not to
give an impact to it when tightening the bolt.
EAS2GC1295INSTALLING THE SHIFT GUIDE AND SHIFT
LEVER ASSEMBLY
1. Install: • Spring “1”
• Pawl pin “2”
•Pawl “3”(to the shift lever “4”)
TIP
Apply the engine oil on the spring, pawl pin and
pawl.
2. Install:
• Shift lever assembly “1”(to the shift guide “2”)
3. Install: • Shift lever assembly “1”
• Shift guide “2”
TIP
• The shift lever assembly is installed at the
same time as the shift guide.
• Apply the engine oil on the segment bolt shaft.
Bolt (stopper lever)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Segment bolt 30 Nm (3.0 m·kgf, 22 ft·lbf)
T R..
2
1
3
4
LT
T R..1
2
1
2

SHIFT SHAFT
6-56
4. Tighten:• Shift guide bolt “1”
EAS2GC1296INSTALLING THE SHIFT SHAFT
1. Install:• Roller “1”
• Shift haft spring “2” (to shift shaft)
• Collar “3” (to shift shaft)
• Shift shaft “4”
TIP
Apply the engine oil on the roller, collar and
shift shaft.
2. Install:• Oil seal
EAS2GC1297INSTALLING THE SHIFT PEDAL
1. Install:• Shift pedal “1”
• Shift pedal bolt “2”
TIP
Align the punch mark “a” on the shift shaft with
the punch mark “b” in the shift pedal. Shift guide bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Shift pedal bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T R..
1
1
LT
E
E
1
2 3
4
New
T R..
a
12 b

OIL PUMP AND BALANCER GEAR
6-57
EAS2GC1298
OIL PUMP AND BALANCER GEAR
Removing the oil pump
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
Right crankcase cover Refer to “CLUTCH” on page 6-41.
1 Oil pump assembly 1
2 Oil pump cover 1
3 Outer rotor 1
4 Dowel pin 1
5 Inner rotor 1
6 Oil pump drive shaft 1
7 Rotor housing 1
For installation, reverse the removal proce-
dure.
2.0 Nm (0.20 mkgf, 1.4 ftIbf)T.R.
5 Nm (0.5 mkgf, 3.6 ftIbf)T.R.
LT
E
3
2
1
4
5
7
6

OIL PUMP AND BALANCER GEAR
6-58
Removing the balancer
OrderPart name Q’tyRemarks
Primary driven gear Refer to “CLUTCH” on page 6-41.
Right crankcase cover Refer to “CLUTCH” on page 6-41.
Generator rotor Refer to “GENERATOR AND STARTER
CLUTCH” on page 6-63.
1 Nut (balancer) 1
2 Nut (primary drive gear) 1
3 Nut (balancer shaft driven gear) 1
4 Lock washer 1
5Balancer 1
6 Straight key 1
7 Conical washer 1
8 Primary drive gear 1
9 Balancer shaft drive gear 1
10 Lock washer 1
11 Balancer weight gear 1
For installation, reverse the removal proce-
dure.
45 Nm (4.5 m kgf, 33 ft Ibf)T.R.
100 Nm (10 m kgf, 72 ft lbf)T.R.
50 Nm (5.0 m kgf, 36 ft Ibf)T.R.
New
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
11
LT

OIL PUMP AND BALANCER GEAR
6-59
EAS2GC1299REMOVING THE BALANCER
1. Loosen:• Balancer nut “1”
• Primary drive gear nut “2”
• Balancer weight gear nut “3”
TIP
Place an aluminum plate “a” between the teeth
of the balancer drive gear “4” and balancer
weight gear “5”.
EAS2GC1300CHECKING THE PRIMARY DRIVE GEAR,
BALANCER SHAFT DRIVE GEAR, AND
BALANCER WEIGHT GEAR
1. Check: • Primary drive gear “1”
• Balancer shaft drive gear “2”
• Balancer weight gear “3”Wear/damage  Replace.
EAS2GC1301CHECKING THE BALANCER
1. Check:
•Balancer
Crack/damage  Replace.
EAS2GC1302CHECKING THE OIL PUMP
1. Check:
• Oil pump drive gear
• Oil pump driven gear
• Oil pump housing
• Oil pump housing coverCracks/damage/wear  Replace the defec-
tive part(s).
2. Measure: • Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification  Replace the oil pump.
1
5
4
2
a
43
a
5

OIL PUMP AND BALANCER GEAR
6-60
3. Check:• Oil pump operationRough movement  Repeat steps (1) and
(2) or replace the defective part(s).
EAS2GC1303ASSEMBLING THE OIL PUMP
1. Install: • Oil pump drive shaft “1”
• Inner rotor “2”
• Dowel pin “3”
TIP
• Apply the engine oil on the oil pump drive shaft and inner rotor.
• Fit the dowel pin into the groove in the inner
rotor.
2. Install: • Outer rotor “1”
TIP
Apply the engine oil on the outer rotor.
3. Install:• Oil pump cover “1”
• Oil pump cover screw “2”
Inner-rotor-to-outer-rotor-tip
clearance
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)
1. Inner rotor
2. Outer rotor
3. Oil pump housing
b
a
1
2
3
c
Oil pump cover screw
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
21
3
1
E
T R..
2
1

OIL PUMP AND BALANCER GEAR
6-61
EAS2GC1304INSTALLING THE OIL PUMP AND BALANC-
ER GEAR
1. Install:• Oil pump assembly “1”
• Oil pump assembly bolt “2”
ECA1DX1023
NOTICE
After tightening the bolts, make sure that
the oil pump turns smoothly.
2. Install:• Balancer weight gear “1”
TIP
Install the balancer weight gear and balancer
shaft with their lower sp lines “a” aligning with
each other.
3. Install:
• Balancer drive gear “1”
TIP
• Align the punched mark “a” on the balancer drive gear with the punched mark “b” on the
balancer weight gear.
• Install the balancer drive gear and crankshaft with the lower splines “c” aligning with each
other. 4. Install:
• Lock washer “1”
• Balancer weight gear nut “2”
• Primary drive gear “3”
• Conical washer “4”
• Primary drive gear nut “5”
• Straight key “6”
•Balancer “7”
• Lock washer “8”
• Balancer nut “9”
TIP
• Apply engine oil to the contact surface and threaded portion of the primary drive gear nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Place an aluminum plate “a” between the teeth of the balancer drive gear “10” and bal-
ancer weight gear “11”.
• Install the conical wash er with its convex sur-
face “b” outward.
Oil pump assembly bolt
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
LOCTITE®
T R..
1
2
LT
Balancer weight gear nut50 Nm (5.0 m·kgf, 36 ft·lbf)
Primary drive gear nut 100 Nm (10 m·kgf, 72 ft·lbf)
Balancer nut 45 Nm (4.5 m·kgf, 33 ft·lbf)
ba
New
T R..
New
T R..
New
T R..

OIL PUMP AND BALANCER GEAR
6-62
5. Bend the lock washer tab.
12
11
10
a
3 45
10 11
a
b
3

GENERATOR AND STARTER CLUTCH
6-63
EAS2GC1305
GENERATOR AND STARTER CLUTCH
Removing the generator
Order Job/Parts to remove Q’tyRemarks
Drain the engine oil. Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Seat and fuel tank Refer to “GENERAL CHASSIS” on page 5-1
and “FUEL TANK” on page 8-1.
Disconnect the AC magneto lead.
Clutch cable
Shift pedal Refer to “SHIFT SHAFT” on page 6-53.
1 Cover (Damper assembly) 1
2 Damper assembly 1
3 Left crankcase cover 1
4Gasket 1
5 Dowel pin 2
6 Starter idle gear 1
7 Bearing 1
8 Starter idle gear shaft 1
9 Generator rotor 1
10 Woodruff key 1
T R..
T R..
T R..
5
5 10
87
6
21
13 3
4
11 9
12
T R..
T R..
T R..LT
LT
T R..
T R..
14
LT
LT