YAMAHA WR 450F 2016 Owner's Manual

IMPORTANT INFORMATION
1-7
EAS20180
IMPORTANT INFORMATION
EAS2GC1020PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before the jobs, completely remove mud, dust, and the like in order to prevent the en-
try of them into the inside during the jobs.
• Before cleaning with high-pressure water of washers, cover the following parts.
Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Hole under the water pump housing
2. Use proper special tools and equipment. See “SPECIAL TOOLS”.
3. During disassembly, check and measure the required parts, and make a record of them
so that you may refer to the record when in-
stalling them. Moreover, arrange gears, cyl-
inders, pistons, and other parts for each
section so as not to confuse or lose them. 4. During disassembly, clean each of the parts,
and store them in trays for each section.
5. Flammable. Keep servicing areas away from any source of fire.
6. During servicing, take special care not to re-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore,
rinse it out with water in good time.
EWA
WARNING
Coolant is potentially harmful and should
be handled with special care.
• If it enters your eyes, wash it away with wa-ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
EAS2GC1021REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
used for repair of the vehicle, including periodic
replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar ap-
pearances or because the quality may be
changed by aging.

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

BASIC SERVICE INFORMATION
1-9
EAS2GC1026
BASIC SERVICE INFORMATION
EAS2GC1027ELECTRICAL SYSTEM
Electrical parts handling
ECA
NOTICE
Never disconnect a battery lead while the
engine is running; otherwise, the electrical
components could be damaged.
ECA
NOTICE
When disconnecting the battery leads from
the battery, be sure to disconnect the nega-
tive battery lead first, then the positive bat-
tery lead. If the positive battery lead is
disconnected first and a tool or similar item
contacts the vehicle, a spark could be gen-
erated, which is extremely dangerous.
TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust us-
ing hot water.
ECA
NOTICE
Be sure to connect the battery leads to the
correct battery terminals. Reversing the
battery lead connections could damage the
electrical components.
ECA
NOTICE
When connecting the battery leads to the
battery, be sure to connect the positive bat-
tery lead first, then the negative battery
lead. If the negative battery lead is connect-
ed first and a tool or similar item contacts
the vehicle while the positive battery lead is
being connected, a spark could be generat-
ed, which is extremely dangerous.
ECA
NOTICE
Make sure that the multi-function display
goes off after pushing and holding the en-
gine stop switch before disconnecting or
connecting any electrical components.

BASIC SERVICE INFORMATION
1-10
ECA
NOTICE
Handle electrical components with special
care, and do not subject them to strong
shocks.
ECA
NOTICE
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
TIP
Push and hold the engine stop switch to turn off
the multi-function display when resetting the
ECU (Electronic Control Unit). Disconnect the
starter motor lead of the starter relay, and then
push the starter switch. Be sure to wait for five
seconds or longer before pushing the start
switch after the multi-function display goes off.Checking the electrical system
TIP
Before checking the electrical system, make
sure that the battery voltage is at least 12 V.
ECA
NOTICE
Never insert the tester probes into the cou-
pler terminal slots. Always insert the probes
from the opposite end “a” of the coupler,
taking care not to loosen or damage the
leads.
ECA
NOTICE
For waterproof couplers, never insert the
tester probes directly into the coupler.
When performing any checks using a water-
proof coupler, use the specified test har-
ness or a suitable commercially available
test harness.
a

BASIC SERVICE INFORMATION
1-11
Checking the connections
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:• Lead
• Coupler
• Connector
ECA
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the
coupler, and then disconnect the coupler.
• There are many types of coupler locks; therefore, be sure to check the type of cou-
pler lock before disconnecting the cou-
pler.
ECA
NOTICE
When disconnecting a connector, do not
pull the leads. Hold both sections of the
connector, and then disconnect the con-
nector. 2. Check:
• Lead
• Coupler
• ConnectorMoisture  Dry with compressed air.
Rust/stains  Connect and disconnect sev-
eral times.
3. Check: • All connectionsLoose connection  Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.
1

BASIC SERVICE INFORMATION
1-12
4. Connect:• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, make sure that both terminals are connected
securely.
• Make sure all connections are tight.
5. Check:• No continuity
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores. Pocket tester
90890-03112
Analog pocket tester YU-03112-C

SPECIAL TOOLS
1-13
EAS2GC1028
SPECIAL TOOLS
The following special tools are required for accurate and complete adjustment and assembly. Using
the correct special tool will help prevent damage ca used by the use of improper tools or improvised
techniques. The shape and tool number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
TIP
• For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use tool number starting with “90890-”.
Tool name/Part number How to use Illustration
Dial gauge & stand set
90890-01252
Dial gauge set
YU-03097-B This tool is used to check
parts for runout or bend.
Crankshaft installer pot
90890-01274
Installing pot
YU-90058 This tool is used to install the
crankshaft.
Crankshaft installer bolt
90890-01275
Bolt
YU-90060 This tool is used to install the
crankshaft.
Adapter (M12)
90890-01278
Adapter #3
YU-90063 This tool is used to install the
crankshaft.
Piston pin puller set
90890-01304
Piston pin puller
YU-01304 This tool is used to remove
the piston pin.

SPECIAL TOOLS
1-14
Radiator cap tester
90890-01325
Mityvac cooling system tester
kit
YU-24460-AThis tool is used to check the
radiator and the radiator cap.
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984 This tool is used to check the
radiator and the radiator cap.
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472 This tool is used to remove or
tighten the steering nut.
Cap bolt wrench
90890-01500
Cap bolt wrench
YM-01500 This tool is used to remove or
tighten the base valve.
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench
YM-01501 This tool is used to loosen or
tighten the damper assem-
bly.
Fork seal driver
90890-01502
Fork seal driver (48)
YM-A0948 This tool is used to install the
oil seal of the front fork.
Spoke nipple wrench (6–7)
90890-01521
Spoke nipple wrench (6–7)
YM-01521 This tool is used to tighten the
spoke.
Tool name/Part number How to use Illustration

SPECIAL TOOLS
1-15
Pocket tester
90890-03112
Analog pocket tester
YU-03112-CThis tool is used to measure
the voltage, current, and re-
sistance of electrical compo-
nents.
Timing light
90890-03141
Timing light
YU-03141 This tool is used to measure
the ignition timing.
Pressure gauge
90890-03153
Pressure gauge
YU-03153 This tool is used to measure
the fuel pressure.
Fuel pressure adapter
90890-03186
Fuel pressure adapter
YM-03186 This tool is used to mount the
pressure gauge.
Test harness S– pressure
sensor (3P)
90890-03207
Test harness S– pressure
sensor (3P)
YU-03207 This tool is used to check the
throttle position sensor input
voltage.
Test harness– lean angle
sensor (6P)
90890-03209
Test harness– lean angle
sensor (6P) This tool is used to check the
lean angle sensor output volt-
age.
FI diagnostic tool sub–lead
90890-03212
FI diagnostic tool sub–lead
YU-03212 This tool is used to connect
the Yamaha diagnostic tool
to a battery.
Test harness– speed sensor
5TJ (3P)
90890-03228
Test harness– speed sensor
5TJ (3P)
YU-03228 This tool is used to check the
speed sensor output voltage.
Yamaha diagnostic tool
90890-03231
Yamaha diagnostic tool (US)
90890-03234 This tool is used to check er-
ror codes or carry out self-di-
agnosis.
Tool name/Part number
How to useIllustration

SPECIAL TOOLS
1-16
Valve guide remover & in-
staller set (ø5.5)
90890-04016
Valve guide remover (5.5
mm)
YM-01122
Valve guide installer (5.5
mm)
YM-04015
Valve guide reamer (5.5 mm)
90890-01196This tool is used to replace
the valve guide.
Valve spring compressor
90890-04019
Valve spring compressor
YM-04019 This tool is used to discon-
nect or connect the valve and
the valve spring.
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044 This tool is used to install the
crankshaft.
Universal clutch holder
90890-04086
Universal clutch holder
YM-91042 This tool is used to hold the
clutch when removing or in-
stalling the clutch boss secur-
ing nut.
Valve lapper
90890-04101
Valve lapping tool
YM-A8998 This tool is used to remove
the valve lifter or lap the
valve.
Tool name/Part number
How to useIllustration
YM-04019
YM-91044