ECU YAMAHA WR 450F 2016 User Guide

ENGINE
3-20
EAS2GC1099ADJUSTING THE VALVE CLEARANCE
TIP
• This section is intended for those who have basic knowledge and skill concerning the ser-
vicing of Yamaha motorcycles (e.g., Yamaha
dealers, service engineers, etc.). Those who
have little knowledge and skill concerning ser-
vicing are requested not to undertake inspec-
tion, adjustment, disassembly, or reassembly
only by reference to this manual. It may lead
to servicing trouble and mechanical damage.
• Make sure that the valve clearance is checked or adjusted while the engine is cold
(at room temperature).
• While the valve clearance is checked or ad- justed, make sure that the piston is positioned
in the top dead center (TDC).
1. Remove: • Seat
• Side cover (left/right)
• Air scoop (left/right)Refer to “GENERAL CHASSIS” on page 5-
1.
• Fuel tank
Refer to “FUEL TANK” on page 8-1.
•ECU
2. Remove:
• Spark plug
• Cylinder head coverRefer to “CAMSHAFT” on page 6-11.
3. Remove: • Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
• O-ring 4. Check:
• Valve clearanceOut of specification  Regulate.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise with a
wrench.
b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the
crankcase cover.
TIP
Check that the alignment mark “c” on the cam-
shaft sprocket and the alignment mark “d” on
the intake camshaft sprocket are aligned with
the edge of the cylinder head.
c. Measure the valve clearance “e” using a
thickness gauge “1”.
TIP
Record the measured reading if the clearance
is incorrect.
12
Valve clearance (cold)Intake 0.13–0.20 mm (0.0051–0.0079 in)
Exhaust 0.18–0.25 mm (0.0071–0.0098 in)
ab
d
c

CHASSIS
3-25
EAS2GC1101
CHASSIS
EAS2GC1102BLEEDING THE BRAKE SYSTEMEWA
WARNING
Bleed the brake system whenever:
• The system is disassembled.
• A brake hose is loosened, disconnected, or replaced.
• The brake fluid level is very low.
• Brake operation is faulty.
1. Remove: • Brake master cylinder cap
• Reservoir diaphragm
• Reservoir float (front brake)
• Protector (rear brake)
TIP
• Be careful not to spill any brake fluid or allow the reservoir to overflow.
• Make sure that there is enough brake fluid be-
fore applying the brake. Ignoring this precau-
tion could allow air to enter the brake system,
considerably lengthening the bleeding proce-
dure.
• If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Re-
peat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
2. Bleed the brake system.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the reservoir to the proper level with the recommended brake fluid.
b. Install the reservoir diaphragm.
c. Connect the plastic hose “1” to the bleed screw “2” securely, and place a container
under the end of the plastic hose. d. Slowly apply the brake several times.
e. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
f. Loosen the bleed screw.
TIP
Loosening the bleed screw will release the
pressure in the brake caliper and cause the
brake lever to contact the throttle grip or the
brake pedal to fully extend.
g. Tighten the bleed screw and then release the brake lever or brake pedal.
h. Repeat steps (d) to (g) until all of the air bub- bles have disappeared from the brake fluid
in the plastic hose.
TIP
During the procedure, keep adding brake fluid
to the reservoir.
ECA
NOTICE
• Wipe off any brake fluid on the brake discs, tires, wheels, etc.
• Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
i. Tighten the bleed screw.
j. Pour brake fluid to the reservoir up to the specified level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30.
EWA
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1
2
A
A. Front
B. Rear
Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
2
1B
T R..

CHASSIS
3-31
• When refilling, be careful that water does not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
EAS2GC1110ADJUSTING THE DRIVE CHAIN SLACKECA
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Shift the transmission into the neutral posi-
tion.
3. Pull the drive chain up above the drive chain guide installation bolt with a force of about
50 N (5.0 kgf, 36 lbf).
4. Check: • Drive chain slack “a”
Out of specification  Regulate.
TIP
Measure drive chain slack between the drive
chain guide and the bottom of the chain as
shown. 5. Adjust:
• Drive chain slack
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn the adjusting bolt “3” in direction “a” or “b” until the specified drive chain slack is ob-
tained.
TIP
• To maintain the proper wheel alignment, ad-just both sides evenly.
• Push the rear wheel forward to make sure that
there is no clearance between the swingarm
end plates and the ends of the swingarm.
d. Tighten the locknut.
e. Tighten the wheel axle nut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1111CHECKING THE FRONT FORK LEGS
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check: • Inner tubeDamage/scratches  Replace.
• Front fork leg (s) Oil leaks between inner tube and outer tube
 Replace the oil seal.
Drive chain slack (on a suitable
stand)
50.0–60.0 mm (1.97–2.36 in)
a
Direction “a”The drive chain slack decreases.
Direction “b” The drive chain slack increases.
Locknut21 Nm (2.1 m·kgf, 15 ft·lbf)
Wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf)
1
32
a
b
T R..
T R..

CHASSIS
3-32
3. Hold the vehicle upright and apply the front brake.
4. Check:
• Front fork operationPush down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation  Correct or replace.
Refer to “FRONT FORK” on page 5-40.
EAS2GC1112CHECKING THE FRONT FORK PROTEC-
TOR GUIDE
1. Check:
• Protector guide “1”Out of specification  Replace.
TIP
The protector guide reaches the limit of its use
when it is worn down to the same height “a” as
of the outer tube circumference.
EAS2GC1113CLEANING THE FRONT FORK OIL SEAL
AND DUST SEAL
1. Remove:
•Protector
• Dust seal “1”
ECA
NOTICE
Be careful not to damage the dust seal and
the inner tube by a driver. 2. Clean:
• Dust seal “a”
• Oil seal “b”
TIP
• Clean the dust seal and oil seal after every
run.
• Apply lithium-soap-based grease on the inner
tube.
EAS2GC1114AIR BLEEDING FROM FRONT FORK
TIP
If the front fork initial movement feels stiff dur-
ing a run, relieve the front fork internal pres-
sure.
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove the air bleed screw “1” and release the internal pressure from the front fork.
1
a
1
LS
a
b

CHASSIS
3-33
3. Tighten:• Air bleed screw
EAS2GC1115ADJUSTING THE FRONT FORK LEGSEWA
WARNING
• Always adjust the left and right front forks evenly. If this is not done, the vehicle may
have poor stability.
• Securely support the vehicle so that there
is no danger of it falling over.
Rebound damping
ECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust: • Rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression dampingECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:• Compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or “b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Air bleed screw1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Direction “a” Rebound damping is increased (sus-
pension is harder).
Direction “b” Rebound damping is decreased (sus-
pension is softer).
Rebound damping adjusting posi-
tionsMaximumFully turned in
Standard 11 clicks out*
Minimum 20 clicks out*
* With the adjuster fully turned in
T R..
1
Direction “a” Compression damping is increased
(suspension is harder).
Direction “b” Compression damping is decreased
(suspension is softer).
Compression damping adjusting
positions Maximum Fully turned in
Standard 13 clicks out*
Minimum 20 clicks out*
* With the adjuster fully turned in
1
a b
ab
1

CHASSIS
3-34
EAS2GC1116CHECKING THE SWINGARM OPERATION
1. Check:• Swingarm smooth action
• Swingarm free playRefer to “SWINGARM” on page 5-65.
EAS2GC1117CHECKING THE REAR SUSPENSION
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:• Rear shock absorber assemblyGas leaks/oil leaks  Replace the rear
shock absorber assembly.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
3. Check: • Rear shock absorber assembly smooth ac-tion
• Rear suspension link smooth action Sit astride the seat and shake your body up
and down several times to check whether
the rear shock absorber assembly operates
smoothly.
Unsmooth operation  Correct or replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
EAS2GC1118ADJUSTING THE REAR SHOCK ABSORB-
ER ASSEMBLY
Use a suitable stand to raise the rear wheel off
the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over. Spring preload
ECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Remove:
• Rear frameRefer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 5-58.
2. Adjust: • Spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Loosen the adjuster “2” until there is some clearance between the spring and the ad-
juster.
c. Measure the spring free length “a”.
d. Turn the adjuster in the direction of “b” or “c” to make an adjustment.
Direction “b”Spring preload is increased (suspen-
sion is harder).
Direction “c” Spring preload is decreased (suspen-
sion is softer).
Spring preload adjusting positionsMinimum 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.

CHASSIS
3-37
2. Tighten:• SpokesUse a spoke nipple wrench “1” for tighten-
ing.
TIP
• Do not give a half turn (180 °) or more for one tightening.
• Make sure that tightening after a break-in is done until the initial looseness in nipples dis-
appears.
• Make sure that tightening is done in stages,
not at a time.
EAS2GC1121CHECKING THE WHEELS
1. Check: • Wheel(s)Damage/out-of-round  Replace.
EWA
WARNING
Never attempt to make any repairs to the
wheel.
TIP
After replacing a tire or a wheel, always bal-
ance the wheel.
EAS2GC1122CHECKING THE WHEEL BEARINGS
1. Check:
• Wheel bearingsRefer to “CHECKING THE FRONT WHEEL”
on page 5-5 and “CHECKING THE REAR
WHEEL” on page 5-10.
EAS2GC1123CHECKING AND ADJUSTING THE STEER-
ING HEAD
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  Adjust the steering
head.
3. Remove: • Handlebar
Refer to “HANDLEBAR” on page 5-33.
• Upper bracket Refer to “STEERING HEAD” on page 5-53.
4. Adjust: • Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the washer “1”.
b. After loosening the ring nut “2” with a steer- ing nut wrench “3”, tighten it to the specified
torque.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly.
Spoke nipple wrench (6–7)
90890-01521
Spoke nipple wrench (6–7) YM-01521
Spokes 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
1
T R..
1
3
2

FRONT WHEEL
5-5
EAS2GC1155REMOVING THE FRONT WHEEL
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:• Front wheel
EAS2GC1156CHECKING THE FRONT WHEEL
1. Check:• Front wheel axleRoll the front wheel axle on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
•Tire(s)
• Front wheelDamage/wear  Replace.
Refer to “CHECKING THE TIRES” on page
3-36 and “CHECKING THE WHEELS” on
page 3-37.
3. Check: • Spokes
Bend/damage  Replace.
Loose  Tighten.
Tap the spokes with a screwdriver.
TIP
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
4. Tighten: • Spokes
Refer to “CHECKING AND TIGHTENING
THE SPOKES” on page 3-36.
TIP
After tightening the spokes, measure the wheel
runout.
5. Measure:• Wheel radial runout “a”
• Wheel lateral runout “b”Out of specification  Repair/replace.
6. Check: •CollarsDamage/wear  Replace.
7. Check: • BearingFront wheel turns roughly or is loose  Re-
place the wheel bearings.
• Oil seals Damage/wear  Replace.
Spokes
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
T R..
a b

REAR WHEEL
5-10
EAS2GC1161REMOVING THE REAR WHEEL
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:• Rear wheel axle nut “1”
3. Loosen:
• Locknut “2”
4. Tighten: • Adjusting bolt “3”
5. Remove: • Rear wheel axle
• Rear wheel
TIP
• Push the rear wheel forward and remove the drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.
EAS2GC1162CHECKING THE REAR WHEEL
1. Check:
• Rear wheel axle
• Rear wheel
• Bearing
• Oil sealsRefer to “CHECKING THE FRONT WHEEL”
on page 5-5.
2. Check: •Tire(s)
• Rear wheelDamage/wear  Replace.
Refer to “CHECKING THE TIRES” on page
3-36 and “CHECKING THE WHEELS” on
page 3-37.
3. Check: • Spokes
Refer to “CHECKING THE FRONT WHEEL”
on page 5-5. 4. Measure:
• Radial wheel runout
• Lateral wheel runoutRefer to “CHECKING THE FRONT WHEEL”
on page 5-5.
EAS2GC1163DISASSEMBLING THE REAR WHEEL
1. Remove:• Oil seals
• Bearing
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 5-6.
EAS2GC1164CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:• Rear wheel sprocketMore than 1/4 tooth wear “a”  Replace the
rear wheel sprocket and the drive sprocket
as a set.
Bent tooth  Replace the rear wheel
sprocket and the drive sprocket as a set.
2. Replace: • Rear wheel sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the rear wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
3
1 2
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
b. Correct
1. Drive chain roller
2. Rear wheel sprocket
Rear wheel sprocket self-locking
nut50 Nm (5.0 m·kgf, 36 ft·lbf)
T R..

HANDLEBAR
5-35
EAS2GC1194REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:•Clutch switch “1”
TIP
Press the projection, and remove it from the
clutch lever assembly.
3. Remove:• Handlebar grip “1”
TIP
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
4. Remove:
• Throttle cable housings “1”
• Throttle grip “2”
TIP
While removing the throttle cable housing, pull
back the rubber cover “3”.
EAS2GC1195CHECKING THE HANDLEBAR
1. Check:• Handlebar
Bends/cracks/damage  Replace.
EWA
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS2GC1196INSTALLING THE HANDLEBAR
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Damper “1”
• Lower handlebar holders“2” (temporarily)
• Handlebar “3”
• Upper handlebar holders “4”
TIP
• Install the lower handl ebar holders with them
side having the greater distance “a” from the
mounting bolt center facing forward.
• Installing the lower handlebar holders in the
reverse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• The upper handlebar holders should be in- stalled with the punch marks “b” facing for-
ward.
• When installing the handlebar, make sure that right and left marks “c” are in place identically
on both sides.
• Install the handlebar so that the projection “d” of the upper handlebar holders is positioned
at the mark on the handlebar as shown.
ECA
Upper handlebar holder bolt28 Nm (2.8 m·kgf, 20 ft·lbf)
T R..