radiator cap YAMAHA WR 450F 2016 User Guide

ENGINE
3-11
3. Remove:• Radiator capSlowly loosen the radiator cap to drain cool-
ant.
TIP
When the radiator cap is loosened, coolant will
gush out transversely; therefore, bring the con-
tainer near to the outlet.
4. Thoroughly flush the cooling system with
clean tap water.
5. Install:
• Copper washer
• Coolant drain bolt
6. Pour coolant.
EWA
WARNING
• If coolant splashes in your eyes, thorough- ly wash them with water and consult a
doctor.
• If coolant splashes on your clothes, quick-
ly wash it away with water and then with
soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA
NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water
is used instead of coolant check, and if
necessary, correct the antifreeze concen-
tration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
7. Install:• Radiator cap 8. Start the engine, warm this up for 3 minutes,
stop it, and then wait for it to cool down.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
9. Check:• Coolant levelRefer to “CHECKING THE COOLANT LEV-
EL” on page 3-10.
EAS2GC1085CHECKING THE RADIATOR CAP
1. Check:• Seal (radiator cap) “1”
• Valve and valve seat “2”
Crack/damage  Replace.
Exist fur deposits  Clean or replace.
EAS2GC1086CHECKING THE RADIATOR CAP VALVE
OPENING PRESSURE
1. Check:
• Radiator cap valve opening pressure
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a. Install the radiator cap tester adapter “2” and the radiator cap tester “3” to the radiator cap
“1,” and activate the tester to check whether
it can stay for 5 to 10 seconds within stan-
dard pressure values.
TIP
Before attaching the cap to the tester, apply
water to its sealing surface.
No stay  Replace.
Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Recommended coolant High quality ethylene glycol
anti-freeze containing anti-cor-
rosion for aluminum engine
Radiator (including all routes) 1.03 L (1.09 US qt, 0.91 Imp.qt)
Coolant mixing ratio 1:1 (Coolant:Water)
New
T R..
Radiator cap valve opening pres-
sure 107.9–137.3 kPa (1.08–1.37 kg/
cm
2,15.6–19.9 psi)

ENGINE
3-12
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EAS2GC1087CHECKING THE COOLANT CIRCULATORY
SYSTEM FOR LEAKS
1. Check:• Coolant level
2. Install: • Radiator cap tester “1”
• Adapter “2”
3. Activate the tester to apply the test pressure.
ECA
NOTICE
• Do not apply such a high pressure as ex- ceeds the test pressure.
• Make sure that a checkup after the cylin-
der head gasket is replaced is made after 3
minutes of warm-up.
• Make sure that coolant is filled up to the
upper level beforehand.
TIP
This model is equipped with an engine auto-
stop system. The engine stops automatically if
left idling for 7 minutes. If the engine stops,
push the start switch or push down the kick-
starter lever to restart the engine.
4. Check:
• Pressure valueNo stay for 5 to 10 seconds at the test pres-
sure value  Correct.
• Radiator
• Radiator hose connections Coolant leaks  Correct or replace.
• Radiator hoses Bulges  Replace
EWA
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
EAS2GC1088ADJUSTING THE CLUTCH LEVER FREE
PLAY
1. Check:
• Clutch lever free play “a”Out of specification  Regulate.
Radiator cap tester
90890-01325
Mityvac cooling system tester kit YU-24460-A
Radiator cap tester adapter 90890-01352
Pressure tester adapter YU-33984
Radiator cap tester 90890-01325
Mityvac cooling system tester kit YU-24460-A
Radiator cap tester adapter 90890-01352
Pressure tester adapter YU-33984
Test pressure value 196 kPa (1.96 kg/cm
2, 27.9 psi)
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)

RADIATOR
7-3
EAS2GC1330HANDLING NOTEEWA
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
EAS2GC1331CHECKING THE RADIATOR
1. Check:• Radiator fins “1”
Obstructions  Clean.
Apply compressed air to the rear of the radi-
ator.
Damage  Repair or replace.
TIP
Correct any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• Radiator hoses
• Radiator pipes
Crack/damage  Replace.

ELECTRICAL COMPONENTS....................................................................... 9-60
CHECKING THE SWITCHES .................................................................. 9-64
CHECKING THE BULBS AND BULB SOCKETS .................................... 9-67
CHECKING THE FUSES ......................................................................... 9-68
CHECKING AND CHARGING THE BATTERY ........................................ 9-69
CHECKING THE RELAYS ....................................................................... 9-72
CHECKING THE DIODE .......................................................................... 9-73
CHECKING THE IGNITION SPARK GAP................................................ 9-73
CHECKING THE SPARK PLUG CAP ...................................................... 9-73
CHECKING THE IGNITION COIL ............................................................ 9-74
CHECKING THE CRANKSHAFT POSITION SENSOR........................... 9-74
CHECKING THE LEAN ANGLE SENSOR............................................... 9-75
CHECKING THE STARTER MOTOR OPERATION ................................ 9-75
CHECKING THE STATOR COIL ............................................................. 9-76
CHECKING THE RECTIFIER/REGULATOR ........................................... 9-76
CHECKING THE SPEED SENS OR ......................................................... 9-77
CHECKING THE FUEL SENDER ............................................................ 9-77
CHECKING THE RESISTER ................................................................... 9-77
CHECKING THE RADIATOR FAN MOTOR ............................................ 9-78
CHECKING THE COOLANT TEMPERATURE SENSOR........................ 9-78
CHECKING THE THROTTLE POSITION SENSOR ................................ 9-79
CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE .. 9-79
CHECKING THE INTAKE AIR PR ESSURE SENSOR ............................ 9-80
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................... 9-80
CHECKING THE FUEL INJECTOR ......................................................... 9-81

TROUBLESHOOTING
10-3
Cooling system
1. Coolant• Low coolant level
2. Radiator • Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump • Damaged or faulty water pump
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
Fuel system
1. Throttle body • Damaged or loose throttle body joint
2. Air filter • Clogged air filter element
Chassis
1. Brake(s) • Dragging brake
Electrical system
1. Spark plug • Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system • Faulty ECU
• Faulty coolant temperature sensor
EAS2GC1417OVERCOOLING
Cooling system
1. Coolant temperature sensor• Faulty coolant temperature sensor
EAS2GC1418POOR BRAKING PERFORMANCE
Chassis
1. Brake(s)• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Defective master cylinder kit
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS2GC1419FRONT FORK OIL LEAKING
Chassis
1. Front fork• Bent, damaged, or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
EAS2GC1420FAULTY FRONT FORK LEGS
Chassis
1. Front fork • Bent or damaged inner tube
• Bent or damaged outer tube
• Broken fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS2GC1421UNSTABLE HANDLING
Chassis
1. Handlebar• Bent or improperly installed handlebar
2. Steering head components • Improperly installed upper bracket
• Improperly installed lower bracket(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg (s) • Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm • Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly (-ies) • Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire (s) • Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear