ABS YAMAHA WR 450F 2016 Owners Manual

IMPORTANT INFORMATION
1-8
EAS2GC1022GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all gaskets and O-rings. All gasket surfaces, oil
seal lips, and O-rings must be cleaned so
that there may be no dust on them.
2. During assembly, always apply proper oil to bearings and proper grease to oil seal lips
before installation.
EAS2GC1023LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace lock washers/plates “1”
and cotter pins with new ones. After the bolt or
nut has been tightened to specification, firmly
bend the lock tabs along a flat of the bolt or nut.
EAS2GC1024BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” with their
manufacturer’s marks or size symbols facing
outward. During installation of an oil seal, make
sure that its main lip faces the oil chamber (the
target to be sealed). Before installation, always
apply a light coat of grease to the oil seal lip.
ECA
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing sur-
faces.
EAS2GC1025CIRCLIPS
When assembling parts, always use new cir-
clips. During installation of a circlip, make sure
that the edge “2” of the circlip “1” is positioned
opposite to the force “3” that the circlip re-
ceives. Install the circ lip with its end aligned
with the center of the spline, without opening
the circlip more than necessary.
1. Oil
2. Lip
3. Spring
4. Grease

MULTI-FUNCTION DISPLAY
1-22
4. To end the setting, push the “RST” button for 2 seconds or more.
TIP
• In a 30-second absence of button operation, the setting will come to an end with the indi-
cated time.
• To reset the seconds, push the “SLCT1” but-
ton or “SLCT2” button.
Changing odometer and tripmeter A/B
(TRIP A/B)
TIP
• The odometer will lock at 99999.
• The tripmeter will reset and continue counting
after 999.9 is reached.
1. Push the “SLCT2” button to change the trip- meter display. The display will change in the
following order:
Odometer TRIP A TRIP B TRIP A 
Odometer.
TIP
To reset the digits, select the tripmeter involved
and push the “RST” button for 2 seconds or
more.
EAS2GC1045CHANGEOVER TO BASIC MODE/RACE
MODE
TIP
• Measurement using the timer function can be made in RACE MODE.
• Indicator will light up as an identifier that
shows RACE MODE has been selected.
• RACE MODE cannot display the functions as in BASIC MODE.
• Changeover to RACE MODE forces the digits for tripmeter A (TRIP A) in BASIC MODE to be
reset.
Changeover from BASIC MODE to RACE
MODE
1. Push the “SLCT1” button and “SLCT2” but- ton for 2 seconds or more at the same time
to change over to RACE MODE.
TIP
Changeover to RACE MODE will put manual
start measurement on standby causing and
to flash. (For manual start, refer to “Putting
measurement on standby” in “RACE MODE”.)

MAINTENANCE AFTER BREAK-IN
1-31
EAS2GC1055
MAINTENANCE AFTER BREAK-IN
After a break-in, perform careful maintenance
to get ready for the next practice or race.
Refer to “PRE-OPERATION INSPECTION
AND MAINTENANCE” on page 3-9.
EAS2GC1056MAJOR MAINTENANCE
1. For the engine• Leaks around the engineCheck for pressure l eaks from the cylinder
head or the cylinder, oil leaks from the
crankcase or the case cover, leaks from the
coolant system, and other leaks.
• Check that the valve, the cylinder head, the cylinder, the piston, and the piston ring fit
one another, and that contact between the
valve and the cylinder head, and that be-
tween the cylinder and the piston are cor-
rect.
• Engine oil change Drain the oil, and check for dirt and foreign
materials such as metal chips. (If any foreign
material is mixed, disassemble and check
the crankcase.)
Pour the specified amount of the recom-
mended oil.
• AC magneto
Check for looseness in mounted areas of
the rotor and the stator.
Check that the connector is not being dis-
connected.
• Silencer Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel (s) Check the wheel for runout. Check the
spoke for looseness.
• Brake(s) Check the brake disc mounting bolt for
looseness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks. • Cable
Grease and adjust cables.
•Drive chain
Lubricate the drive chain and adjust its ten-
sion.
• Fuel tank
Clean the inside of the fuel tank. Check for
leaks.
• Suspension
Check for oil leaks in the front fork or the rear
shock absorber. Check that the mounted
conditions are good.
• Sprocket Check for looseness in the sprocket mount-
ed on the rear wheel.
• Mounting bolts and nuts
Check mounted areas for looseness.
ECA
NOTICE
After a break-in or before each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them. (Refer to “TORQUE-CHECK
POINTS” on page 1-32.)
• Greasing and oilingAlways grease or oil the specified points.

TORQUE-CHECK POINTS
1-32
EAS2GC1057
TORQUE-CHECK POINTS
Frame constructionFrame to rear frame
Frame to engine protector
Combined seat and fuel tank Fuel tank to frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Seat Seat to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear Link Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Mounting of rear shock absorber Rear shock absorber and frame
Mounting of swingarm Tightening of pivot shaft
Wheel (s) Mounting of wheel Front Tightening of wheel axle
Tightening of axle holder
Tightening of spoke nipple
Rear Tightening of wheel axle Wheel to rear wheel sprocket
Tightening of spoke nipple
Brake(s) Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handle-
bar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Shift pedal Shift pedal to shift shaft

CHASSIS SPECIFICATIONS
2-8
Rear brakeType Hydraulic single disc brake
Operation Right foot operation
Brake pedal position 5.0 mm (0.20 in)
Rear disc brake
Disc outside diameter  thickness 245.0  4.0 mm (9.65  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm (1.00 in)
Specified brake fluid DOT 4
Steering Steering bearing type Taper roller bearing
Center to lock angle (left) 43.0 °
Center to lock angle (right) 43.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/Hydraulic damper
Front fork travel 310.0 mm (12.20 in)
Fork spring free length 470.0 mm (18.50 in)
Limit 465.0 mm (18.31 in)
Fork spring installed length 470.0 mm (18.50 in)
Spring rate K1 4.50 N/mm (0.46 kgf/mm, 25.71 lbf/in)
Spring stroke K1 0.0–310.0 mm (0.00–12.20 in)
Inner tube outer diameter 48 mm (1.9 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available Yes
Recommended oil Yamaha Suspension Oil S1
Quantity 545.0 cm
3 (18.43 US oz, 19.18 Imp.oz)
Rebound damping adjusting positions
Minimum 20 clicks out*
Standard 11 clicks out*
Maximum Fully turned in * With the adjuster fully turned in
Compression damping adjusting positions Minimum 20 clicks out*
Standard 13 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in

CHASSIS SPECIFICATIONS
2-9
Rear suspensionType Swingarm (link suspension)
Spring/shock absorber type Coil spring/Gas-hydraulic damper
Rear shock absorber assembly travel 126.0 mm (4.96 in)
Spring free length 275.0 mm (10.83 in)
Spring installed length 263.0 mm (10.35 in)
Spring rate K1 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in)
Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)
Optional spring available Yes
Enclosed gas/air pressure (STD) 980 kPa (9.8 kgf/cm
2, 139.4 psi)
Spring preload adjusting positions
Minimum Position in which the spring is turned in 1.5 mm
(0.06 in) from its free length.
Standard Position in which the spring is turned in 12 mm
(0.47 in) from its free length.
Maximum Position in which the spring is turned in 18 mm
(0.71 in) from its free length.
Rebound damping adjusting positions Minimum 30 clicks out*
Standard 14 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in
Compression damping setting
(for fast compression damping)Minimum 2 turns out*
Standard 1-3/4 turns out*
Maximum Fully turned in
* With the adjuster fully turned in
Compression damping setting
(for slow compression damping)Minimum 20 clicks out*
Standard 10 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in
Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in)
Drive chainSize/manufacturer DID520VM2/DAIDO
Number of links 114
Drive chain slack (on a suitable stand) 50.0–60.0 mm (1.97–2.36 in)
15-link length limit 239.3 mm (9.42 in)

TIGHTENING TORQUES
2-18
Front brake disc boltM6 6 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rear brake disc bolt M6 6 14 Nm (1.4 m·kgf, 10 ft·lbf)
Footrest bracket bolt M10 4 55 Nm (5.5 m·kgf, 40 ft·lbf)
Sidestand bolt M10 1 25 Nm (2.5 m·kgf, 18 ft·lbf)
Rear brake pedal bolt M8 1 26 Nm (2.6 m·kgf, 19 ft·lbf)
Rear brake pedal position locknut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake master cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake master cylinder reservoir
cap bolt M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Rear brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear wheel axle nut M22 1 125 Nm (12.5 m·kgf, 90 ft·lbf)
Drive chain puller adjust bolt and
locknut M8 2 21 Nm (2.1 m·kgf, 15 ft·lbf)
Rear wheel sprocket nut M8 6 50 Nm (5.0 m·kgf, 36 ft·lbf)
Nipple (spoke) — 72 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear brake disc cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake caliper protector bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Engine mounting bolt (upper side) M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Engine mounting bolt (front side) M10 1 55 Nm (5.5 m·kgf, 40 ft·lbf)
Engine mounting bolt (lower side) M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Engine bracket bolt (upper side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine bracket bolt (front side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Rear frame and frame bolt M8 4 38 Nm (3.8 m·kgf, 27 ft·lbf)
Engine guard bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft and nut M16 1 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear shock absorber assembly up-
per bolt M10 1 56 Nm (5.6 m·kgf, 41 ft·lbf)
Rear shock absorber assembly low-
er bolt M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Rear shock absorber locknut M60 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Relay arm bolt (swingarm side) M14 1 70 Nm (7.0 m·kgf, 51 ft·lbf)
Connecting arm bolt (relay arm side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (frame side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Swingarm and brake hose holder
screw M5 4 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Drive chain tensioner bolt (upper
side) M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES RemarksLT
LT
LT

LUBRICATION POINTS AND LUBRICANT TYPES
2-22
EAS2GC1070CHASSISStarter idle gear inner surface, thrust surfaces
Starter clutch drive gear inner surface, thrust surfaces
Cylinder head cover gasket
Yamaha bond
No.1215
(Three bond No.1215®)
Crankcase mating surface Yamaha bond
No.1215
(Three bond No.1215®)
Stator assembly lead grommet Yamaha bond
No.1215
(Three bond No.1215®)
Lubrication point Lubricant types
Upper bearings (steering head)
Upper bearings and bearing race cover (steering head)
Lower bearings and oil seal lip (steering head)
Steering stem threads and nut contacting surface
Pivot shaft bearing
Swingarm pivot portion (collar side surface and thrust bearing)
Swingarm pivot portion (collar outer surface)
Swingarm pivot portion (oil seal lip)
Pivot shaft outer surface
Relay arm bearing and oil seal lip
Relay arm thrust washer surface (both sides)
Relay arm collar outer surface and bolt outer surface
Relay arm bolt threads (swingarm side)
Connecting arm bearing and oil seal lip
Connecting arm collar outer surface and bolt outer surface
Rear shock absorber assembly collar outer surface and dust seal lip (upper
side)
Rear shock absorber assembly bearing and dust seal lip (lower side)
Brake pedal pivot portion (O-ring and bolt outer surface)
Front wheel oil seal lip
Front wheel axle outer surface
Rear wheel oil seal lip
Rear wheel axle outer surface
Sidestand pivot portion and collar outer surface
Push rod contacting portion (front brake master cylinder)
Front brake lever bolt outer surface Lubrication point
Lubricant types
E
E
LS
LS
LS
LS
M
M
M
M
M
M
M
M
M
M
M
M
M
LS
LS
LS
LS
LS
LS
S
S

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.

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