coolant YAMAHA WR 450F 2016 Owner's Manual

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.

WATER PUMP
7-4
EAS2GC1332
WATER PUMP
Removing the water pump
OrderPart name Q’tyRemarks
Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Right crankcase cover Refer to “CLUTCH” on page 6-41.
1 Water pump housing 1
2 Dowel pin 2
3Gasket 1
4Collar 1
5Pin 1
6 Impeller shaft assembly 1
7 Oil seal 1
8 Bearing 1
9 Oil seal 1
For installation, reverse the removal proce-
dure.
LS
LS
7
6
2 2
3
1
854
New
New
New
E
9
New
E
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.

WATER PUMP
7-5
EAS2GC1333REMOVING THE OIL SEAL
TIP
• Remove the oil seal when the coolant level changes frequently more than usual, coolant
has discolored, or engine oil has become
milky.
• Do not use the removed oil seal.
1. Remove:• Oil seals “1”
EAS2GC1334CHECKING THE WATER PUMP
1. Check:
• Water pump housing cover
• Impeller shaftCracks/damage/wear  Replace.
EAS2GC1335CHECKING THE BEARING
1. Check:
• BearingRotate the inner race with your finger.
Rough spot/seizure  Replace.
EAS2GC1336INSTALLING THE OIL SEAL
1. Install:
• Oil seals “1”
TIP
• Apply the lithium-soap-based grease on the oil seal lip.
• Install the oil seal with its manufacture’s marks or numbers facing the right crankcase
cover “2”. 2. Install:
• Bearing “1”
TIP
Install the bearing by pressing its outer race
parallel.
EAS2GC1337ASSEMBLING THE WATER PUMP
1. Install:
• Impeller shaft assembly “1”
•Pin “2”
• Collar “3”
• Circlip “4”
TIP
• Take care so that the oil seal lip is not dam-aged or the spring does not slip off its posi-
tion.
• When installing the impeller shaft, apply the engine oil to the oil seal lip, the bearing, and
the impeller shaft.
1
1
New
1
1New
New
LS
LS2
New
4
1
23New
E

WATER PUMP
7-6
2. Install:• Dowel pin “1”
• Gasket “2”
3. Install: • Water pump housing “1”
• Water pump housing bolt “2”
• Washer “3”
• Coolant drain bolt “4” Water pump housing bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
New
21
1New
T R..
New
T R..
2
2
4 3
1
New

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

COOLING SYSTEM
9-25
1. Joint connector
2. Joint connector
3. Joint connector
7. Main relay
9. Battery
10.Frame ground
11.Starter relay
12.Main fuse
22.ECU (engine control unit)
27.Radiator fan motor relay
28.Radiator fan motor fuse
29.Radiator fan motor
30.Joint connector
32.Coolant temperature sensor
48.Frame ground
50.Negative battery lead

COOLING SYSTEM
9-26
EAS2GC1372TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
Before troubleshooting, remove the following part(s):
1. Seat
2. Side cover (left)
3. Air scoop (left/right)
4. Fuel tank1. Check the fuse. Refer to “CHECKING THE FUSES”
on page 9-68. NG

Replace the fuse(s).
OK 
2. Check the battery. Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 9-69. NG

• Clean the battery terminals.
• Recharge or replace the battery.
OK 
3. Check the main relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG

Replace the main relay.
OK 
4. Check the radiator fan motor. Refer to “CHECKING THE RADIA-
TOR FAN MOTOR” on page 9-78. NG

Replace the radiator fan motor.
OK 
5. Check the radiator fan motor relay. Refer to “CHECKING THE RE-
LAYS” on page 9-72. NG

Replace the radiator fan motor relay.
OK 
6. Check the coolant temperature sen- sor.
Refer to “CHECKING THE COOL-
ANT TEMPERATURE SENSOR”
on page 9-78. NG

Replace the coolant temperature sensor.
OK 
7. Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM” on
page 9-16. NG

Properly connect or repair the cooling sys-
tem’s wiring.
OK 
Replace the ECU.

FUEL INJECTION SYSTEM
9-29
1. Joint connector
2. Joint connector
3. Joint connector
4. AC magneto
7. Main relay
9. Battery
10.Frame ground
11.Starter relay
12.Main fuse
15.Indicator light
16.Engine trouble warning light
22.ECU (engine control unit)
25.Injector
30.Joint connector
31.Intake air temperature sensor
32.Coolant temperature sensor
33.Throttle position sensor
34.Intake air pressure sensor
35.Lean angle sensor
36.Engine stop switch
37.Neutral switch
38.Diode
39.Starting circuit cut-off relay
40.Clutch switch
42.Joint connector
48.Frame ground
50.Negative battery lead

FUEL INJECTION SYSTEM
9-42
TIP
• Make sure that the engine is completely cool before checking the coolant temperature sensor.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.
Fail-safe system Able to start engine
Able to drive vehicle
Diagnostic code No. 06
Diagnostic tool display Displays the coolant temperature.
Procedure Compare the actually measured coolant temperature with the
Yamaha diagnostic tool display value.
Item Probable cause of malfunc-
tion and check Maintenance jobConfirmation of service
completion
1 Connection of coolant tem- perature sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins). Improperly connected

Connect the coupler securely
or repair/replace the wire har-
ness. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 2.
2 Connection of wire harness ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins). Improperly connected

Connect the coupler securely
or repair/replace the wire har-
ness. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 3.
3 Wire harness continuity. Open or short circuit  Re-
place the wire harness.
Between coolant temperature
sensor coupler and ECU cou-
pler.
green/white–green/white
black/blue–black/blue Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 4.
4 Installed condition of coolant temperature sensor.
Check for looseness or
pinching. Improperly installed sensor

Reinstall or replace the
sensor. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 5.

FUEL INJECTION SYSTEM
9-43
TIP
• Make sure that the engine is completely cool before checking the intake air temperature sensor.
• Before troubleshooting, disconnect the starter motor lead from the starter relay.
5 Defective coolant tempera-
ture sensor. Execute the diagnostic mode.
(Code No. 06)
When engine is cold:
Displayed temperature is
close to the ambient temper-
ature.
The displayed temperature is
not close to the ambient tem-
perature. 
Check the cool-
ant temperature sensor.
Replace if defective.
Refer to “CHECKING THE
COOLANT TEMPERATURE
SENSOR” on page 9-78. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 6.
6 Malfunction in ECU. Replace the ECU.
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.
Fail-safe system Able to start engine
Able to drive vehicle
Diagnostic code No. 05
Diagnostic tool display Displays the intake air temperature.
Procedure Compare the actually measured intake air temperature with the
Yamaha diagnostic tool display value.
Item Probable cause of malfunc-
tion and check Maintenance jobConfirmation of service
completion
1 Connection of intake air tem- perature sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins). Improperly connected

Connect the coupler securely
or repair/replace the wire har-
ness. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 2.
2 Connection of wire harness ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler and
check the pins (bent or bro-
ken terminals and locking
condition of the pins). Improperly connected

Connect the coupler securely
or repair/replace the wire har-
ness. Push the start switch.
Fault code number is not dis-
played
 Service is finished.
Fault code number is dis-
played  Go to item 3.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.