YAMAHA WR 450F 2016 Owners Manual

GENERATOR AND STARTER CLUTCH
6-64
11 Starter clutch1
12 Starter clutch drive gear 1
13 Crankshaft position sensor 1
14 Stator 1
For installation, reverse the removal proce-
dure.
Removing the generator
Order Job/Parts to remove Q’tyRemarks
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

GENERATOR AND STARTER CLUTCH
6-65
EAS2GC1306REMOVING THE GENERATOR
1. Remove:• Generator rotor nut “1”
• Washer
2. Remove: • Generator rotor “1”
(with the rotor puller “2”)
• Woodruff key
EAS2GC1307CHECKING THE STARTER CLUTCH
1. Check: • Starter clutch rollers
Damage/wear  Replace.
2. Check: • Starter clutch idle gear
• Starter clutch gearBurrs/chips/roughness/wear  Replace the
defective part (s). 3. Check:
• Starter clutch gearDamage/pitting/wear  Replace the starter
clutch gear.
4. Check: • Damper assembly
Damage/pitting/wear  Replace the damp-
er assembly.
Check the gear of the starter motor arma-
ture.
5. Check: • Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch drive gear “1” onto the starter clutch and hold the starter clutch.
b. When turning the starter clutch drive gear
clockwise “A”, the starter clutch and the
starter clutch drive gear should engage, oth-
erwise the starter clutch is faulty and must
be replaced.
c. When turning the starter clutch drive gear counterclockwise “B”, it should turn freely,
otherwise the starter clutch is faulty and
must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Rotor puller90890-04142
Rotor puller YM-04142
1
1
2
1
A
B

GENERATOR AND STARTER CLUTCH
6-66
EAS2GC1308INSTALLING THE STARTER CLUTCH
1. Install:• Stator “1”
• Stator bolt “2”
• Crankshaft position sensor “3”
• Holder “4”
• Crankshaft position sensor bolt “5”
TIP
• Pass the stator coil lead between ribs “a”, and put it in part “b” so that there is no slack.
• Pass crankshaft sensor lead “c” over stator
coil lead “d”.
• Pass the crankshaft sensor lead outside of rib “a” and place the excess end next to boss “e”.
• Make sure that the end surface of holder “f” does not get caught on rib “a”.
• Place the stator coil lead and crankshaft sen-
sor lead inside the U-shaped space “g”of the
holder.
• Tighten the stator bolt using the T25 bit.
• Apply the sealant to the grommet of the AC
magneto lead. 2. Install
• Starter clutch drive gear “1”
TIP
Apply the engine oil on the starter clutch drive
gear inner circumference.
Stator bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LOCTITE®
Crankshaft position sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Yamaha bond No. 1215 90890-85505
(Three bond No.1215®)
T R..
T R..
g
d
c
ea
a
b
f
LT

GENERATOR AND STARTER CLUTCH
6-67
3. Install:• Starter clutch “1”To generator rotor “2”.
EAS2GC1309INSTALLING THE GENERATOR
1. Install:
• Woodruff key “1”
• Generator rotor “2”
TIP
• Clean the contact surfaces of the tapered por-tions of the crankshaft and generator rotor.
• When installing the woodruff key, make sure that its flat surface “a” is in parallel with the
crankshaft center line “b”.
• When installing the generator rotor, align the keyway “c” of the generator rotor with the
woodruff key.
2. Install: • Washer
• Generator rotor nut “1” 3. Install:
• Starter idle gear shaft “1”
• Bearing “2”
• Starter idle gear 2 “3”
TIP
Apply the engine oil on the starter idle gear
shaft, bearing and idle gear inner circumfer-
ence.
4. Install:
• Dowel pin
• Crankcase cover gasket
• Left crankcase cover “1”
• Lead holder “2”
• Crankcase cover bolt
• Neutral switch lead “3”
TIP
• Pass the AC magneto lead “4” under the left crankcase cover “a” as shown.
• Tighten the bolts in stage, using a crisscross
pattern.
Starter clutch bolt
16 Nm (1.6 m·kgf, 12 ft·lbf)
LOCTITE®
Generator rotor nut 65 Nm (6.5 m·kgf, 47 ft·lbf)
21
LT
T R..
2
C
1 1
1a
b
T R..
Crankcase cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
1
2 1
2
3
New
T R..

GENERATOR AND STARTER CLUTCH
6-68
5. Install:• Washer “1”
• Damper assembly “2”
• Washer “3”
TIP
Apply the engine oil to the shaft and washers.
6. Install:• Cover (damper assembly) “1”
• Bracket “2”
•Bolt “3”
TIP
Install the cover (damper assembly) with its
mark “a” facing upward. Bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
4
1 a
1
2
3
2
1
2
3
T R..
1a3
3
2

CRANKCASE
6-69
EAS2GC1310
CRANKCASE
Separating the crankcase
OrderPart name Q’tyRemarks
Engine Refer to “ENGINE REMOVAL” on page 6-1.
Piston Refer to “CYLINDER AND PISTON” on page
6-31.
Balancer Refer to “OIL PUMP AND BALANCER
GEAR” on page 6-57.
Kick shaft assembly Refer to “KICKSTATER” on page 6-50.
Segment Refer to “SHIFT SHAFT” on page 6-53.
Stator Refer to “GENERATOR AND STARTER
CLUTCH” on page 6-63.
1 Timing chain guide (exhaust side) 1
2 Timing chain guide stopper plate 1
3 Timing chain 1
4 Bolt [L = 45 mm (1.77 in)] 6
5 Bolt [L = 60 mm (2.36 in)] 4
6 Bolt [L = 75 mm (2.95 in)] 2
7 Right crankcase 1
8 Left crankcase 1
9 Dowel pin 2
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
3
1
5
2 6410
5
5
4
4 4 46
9 7
8
11
9
LT
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
LT

CRANKCASE
6-70
10 Crankshaft1
11 Oil nozzle 1
For assembly, reverse the disassemble pro-
cedure.
Separating the crankcase
Order Part name Q’tyRemarks
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
3
1
5
2 6410
5
5
4
4 4 46
9 7
8
11
9
LT
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
LT

CRANKCASE
6-71
Removing the bearing and oil seal
OrderPart name Q’tyRemarks
Transmission Refer to “TRANSMISSION” on page 6-77.
Shift cam and shift fork Refer to “TRANSMISSION” on page 6-77.
1 Circlip 1
2Oil seals 3
3 Bearing 11
For installation, reverse the removal proce-
dure.
LT
LT
LT
LT
LT
12 2
3
3
33
3
3
3
3
3 3
New
NewLT

CRANKCASE
6-72
EAS2GC1311DISASSEMBLING THE CRANKCASE
1. Separate:• Right crankcase
• Left crankcase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the crankcase bolts.
TIP
Loosen each bolt 1/4 of a turn at a time and af-
ter all the bolts are loosened, remove them.
b. Remove the right crankcase “1”.
TIP
• Place the crankcase with its left side down-ward and split it by inserting a screwdriver tip
into the splitting slit “a” in the crankcase.
• Lift the right crankcase horizontally while light-
ly patting the crankcase splitting slit and the
engine mounting boss using a soft hammer,
and leave the crankshaft and the transmission
with the left crankcase.
ECA33DD041
NOTICE
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case. Do
not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If the cases do not
separate, check for a remaining case bolt or
fitting. Do not force. c. Remove the dowel pins and O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1312REMOVING THE CRANKCASE BEARING
1. Remove:
• Bearing “1”
TIP
• Remove the bearing from the crankcase by pressing its inner race.
• Do not use the removed bearing.
EAS2GC1313CHECKING THE TIMING CHAIN, TIMING
CHAIN GUIDE, OIL STRAINER
1. Check:• Timing chainStiffness  Replace the camshaft sprocket,
timing chain and crankshaft sprocket as a
set.
2. Check: • Timing chain guide
Damage/wear  Replace
EAS2GC1314CHECKING THE CRANKCASE
1. Wash:
• Crankcase
TIP
• Wash the crankcase in a mild solvent.
• Remove any remaining gasket from the
crankcase mating surface.
2. Check: • CrankcaseCrack/damage  Replace.
1
a

CRANKCASE
6-73
• Oil delivery passagesObstruction  Blow out with compressed
air.
EAS2GC1315INSTALLING THE OIL SEAL
1. Install:
• Oil seal “1” (to left crankcase)
EAS2GC1316ASSEMBLING THE CRANKCASE
1. Install:• Bearing cover plate
TIP
• Install the bearing by pressing its outer race parallel.
• To prevent the bearing cover plate screw (crankshaft) “1” from becoming loose, crimp
the screw head periphery “a” into the concave
“b” using a punch etc. In so doing, take care
not to damage the screwdriver receiving hole
in the screw.
2. Apply: • Sealant(to the crankcase mating surface) 3. Install:
• Dowel pins “1”
• Crankcase “2”(to the left crankcase)
TIP
• Apply the lithium-soap-based grease on the
O-ring.
• Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer.
• When installing the crankcase, the connecting rod should be positioned at top dead center
(TDC).
• Tighten the bolts in a crisscross pattern in two
(2) stages, with 1/4 turn each.
Installed depth “a”
0.0–0.5 mm (0.00–0.02 in)
Bearing cover plate 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Bearing cover plate (crankshaft) 18 Nm (1.8 m·kgf, 13 ft·lbf)
New
1
a
T R..
a
b
1
1
Yamaha Bond No.121590890-85505
(Three Bond No.1215®)
Crankcase bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
3. 45 mm (1.77 in)
4. 60 mm (2.36 in)
5. 75 mm (2.95 in)
T R..
4 3
5
3
3
3
4 5
4
3
1
12