fuel YAMAHA WR 450F 2016 Owner's Manual

TIGHTENING TORQUES
2-19
Drive chain tensioner bolt (lower
side)M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Drive chain support bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain support nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain guide bolt M5 3 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear frame and left cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (front side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (rear side) M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Fuel tank bracket bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bracket bolt (rear side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump bolt M5 6 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel sender screw M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel inlet pipe screw M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Fuel tank cap cover bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Seat set bracket and fuel tank screw M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Left side cover bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Right side cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator guard and air scoop bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear fender bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt (rear side) M6 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Mud flap screw — 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Headlight body and headlight stay
bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Multi-function meter nut M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Multi-function meter bracket bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake hose guide and head-
light stay bolt M5 1 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Plate 1 and front fork protector bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Plate 2 and front fork protector
screw — 2 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Speed sensor lead holder and
speed sensor lead bracket bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Speed sensor lead bracket and low-
er bracket bolt M6 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Starter relay and positive battery
lead bolt M6 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES Remarks

CABLE ROUTING DIAGRAM
2-36
1. Clamp
2. Throttle position sensor lead
3. Joint coupler
4. Intake air temperature sensor lead
5. Intake air pressure sensor lead
6. Wire harness
7. Injector lead
8. Injector coupler
9. Throttle body
10. Cylinder head breather hose
11. Engine ground sub-lead
12. Plate
13. Engine ground sub-lead coupler
14. Starter motor lead
15. Plastic band
16. Fuel sender coupler
17. High tension cord
18. Spark plug cap
19. Cylinder head cover
20. Fuel hose
21. Fuel sender
22. Sub-wire harness
23. Radiator breather hose
24. Radiator hose
25. Down tube
26. Starter motor cover
27. Starter motor
28. AC magneto lead
29. Clutch cable
30. Neutral switch lead
31. Radiator
32. Breather hose clamp
33. Grommet (high tension cord)
34. ECU
35. Air filter case
36. Sub-wire harness coupler
37. Engine bracket
A. Fix the wire harness, clutch switch lead and start switch lead by the plasti c clamp, and insert the
projection of the plastic clamp into the hole in the
sheet metal of the radiator.
B. Route each lead so that the leads are not pinched between the tank rail and air filter joint.
C. Insert the projection of the wire harness into the hole in the frame.
D. Pass the cylinder head breather hose between the throttle cable and engine ground sub-lead.
E. Insert the engine ground sub-lead coupler into the plate, facing inside the vehicle.
F. Connect the sub-wire harness to the wire har- ness.
G. Pass the high tension cord above the fuel hose.
H. ±10°
I. Install the spark plug cap with this facing the right
of the vehicle.
J. Push the spark plug cap home, where there shall be no gap between it and the cylinder head cover.
K. Pass the radiator breather hose between the down tubes.
L. Pass the starter motor lead under the starter mo- tor shaft.
M. Pass the sub-wire harness between the ECU and the air filter case.
N. Apply adhesive to the s lit and inside of the grom-
met, and then fix the grommet according to the
specified dimensions.
O. 50±3 mm (2.0±0.12 in)
P. Insert the coupler of the sub-wire harness into the
rib of the air filter case. Q. Clamp the starter motor lead, point the clamp
downward, and insert it into the frame.
R. Route the radiator breather hose through be- tween the radiator hose, down tube and engine
bracket.

CABLE ROUTING DIAGRAM
2-38
1. Cable guide
2. Speed sensor lead
3. Joint coupler
4. Ground lead
5. Throttle position sensor lead
6. Throttle position sensor coupler
7. Radiator breather hose
8. Radiator hose
9. Fuel hose
10. Coolant temperature sensor coupler
11. Radiator fan motor lead
12. Intake air pressure sensor coupler
13. Intake air temperature sensor coupler
14. Start switch coupler
15. Radiator fan motor coupler
16. Clutch switch coupler
17. Air filter case
18. Plate
19. Bracket
20. Radiator hose clamp
A. Pass the wire harness under the start switch lead
and clutch switch lead.
B. Insert and fix the joint co upler to the plate. After
fixing it, attach the cover.
C. Pass the throttle position sensor lead to the out- side of the tension arm (the outside of the vehi-
cle).
D. After connecting the throttle position sensor cou- pler, attach the cover.
E. Pass the radiator breather hose to the outside of the tension arm and the throttle position sensor
lead (the outside of the vehicle), and to the front
of the radiator hose (the side of the vehicle).
F. Attach the coupler cover to the coolant tempera- ture sensor coupler.
G. Pass the radiator fan motor lead to the inside of the tension arm (the side of the vehicle).
H. Install the ground lead terminal between the plate and the bolt.
I. Fix the ground lead terminal to the detent in the plate. For the ground lead terminal, either side
will do.
J. Detent
K. Route the radiator breather hose between the frame and the radiator fan motor lead coupler so
that the breather hose is not pinched.
L. Install the radiator hose clamp with the locking portion facing the front of the vehicle and tighten
the screw from the right side of the vehicle.
M. Install the radiator hose with the positioning mark facing the rear of the vehicle.

CABLE ROUTING DIAGRAM
2-40
1. Battery negative lead
2. Fuel hose
3. Fuel pump coupler
4. Fuel pump lead
5. Resistor
6. Resistor coupler
7. Battery positive lead
8. Lean angle sensor
9. Starter motor lead
10. Radiator fan motor relay (blue tape)
11. Main relay (red tape)
12. Wire harness
13. Ground lead coupler
14. Starter relay coupler
15. Starter relay
16. Cross member
17. Diode
18. Taillight lead
19. Clamp
20. Fuel tank
21. Damper
22. Rear frame
23. Side cover 6
24. Plastic locking tie
A. After connecting the fuel pump coupler, attach the coupler cover.
B. Pass the fuel hose to the front of the battery.
C. Route the resistor lead to the outside of the leads.
D. Connect the battery positive lead to the starter re- lay terminal (in the left side of the vehicle).
E. Insert the protruding end of the wire harness into
the battery bracket hole and holder plate hole.
F. After connecting the negative lead coupler, place it on the right side of the battery.
G. Route the diode under the cross member and place it on top of the rear fender.
H. Secure the two ends of the taillight coupler with the starter motor lead.
I. Route the taillight lead so that it does not slack at
the rear of the vehicle.
J. Clamp the taillight lead and insert the clip into the rear fender. Clamp it so that the lock faces in-
ward, and then cut off the excess end.
K. Lower end of the rear frame
L. Clamp it so that the lock of the plastic locking tie
faces downward, insert the end into the rear
frame and side cover 6, and then cut off the ex-
cess end. After cutting off the excess end, make
sure that the plastic locki ng tie does not protrude
from the lower end of the rear frame.
M. Clamp it so that the lock of the plastic locking tie
faces downward, and then pass the end between
the fuel hose and rear frame.
N. Clamp the wire harness at the position of the white tape.
O. Route the battery positive lead under the cross member.
P. After connecting the battery positive lead in the direction indicated in the illustration, put the cover
on.

3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................. 3-1
INTRODUCTION ........................................................................................ 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ....................... .......................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 3-2
MAINTENANCE INTERVALS FOR COMPETITION USE ......................... 3-4
PRE-OPERATION INSPECTION AND MAINTENANCE ................................. 3-9
GENERAL INSPECTION AND MAINTENANCE........................................ 3-9
ENGINE .......................................................................................................... 3-10
CHECKING THE COOLANT LEVEL ........................................................ 3-10
CHECKING THE COOLING SYSTEM ..................................................... 3-10
CHANGING THE COOLANT.................................................................... 3-10
CHECKING THE RADIATOR CAP .......................................................... 3-11
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ....... 3-11
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-12
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-13
LUBRICATING THE THROTTLE CABLE ................................................ 3-14
CLEANING THE AIR FILTER ELEMENT................................................. 3-14
CHECKING THE THROTTLE BODY JOINT ............................................ 3-15
CHECKING THE BREATHER HOSES .................................................... 3-15
CHECKING THE EXHAUST SYSTEM............................. ........................ 3-15
CHECKING THE FUEL LINE ................................................................... 3-16
CHECKING THE ENGINE OIL LEVEL............................. ........................ 3-16
CHANGING THE ENGINE OIL ................................................................ 3-17
ADJUSTING THE ENGINE IDLING SPEED ......... ................................... 3-19
ADJUSTING THE VALVE CLEARANCE ................................................. 3-20
CLEANING THE SPARK ARRESTER ..................................................... 3-24
CHASSIS ........................................................................................................ 3-25
BLEEDING THE BRAKE SYST EM .......................................................... 3-25
CHECKING THE BRAKE HOSE .............................................................. 3-26
ADJUSTING THE FRONT BRAKE .......................................................... 3-26
ADJUSTING THE REAR BRAKE ............................................................. 3-27
CHECKING THE FRONT BR AKE PADS ................................................. 3-27
CHECKING THE REAR BRAKE PADS ........................... ........................ 3-29
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-30
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-30
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-31
CHECKING THE FRONT FORK LEGS ................................................... 3-31
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-32
CLEANING THE FRONT FORK OI L SEAL AND DUST SEAL ................ 3-32
AIR BLEEDING FROM FRONT FORK .................................................... 3-32
ADJUSTING THE FRONT FORK LEGS .................................................. 3-33
CHECKING THE SWINGARM OPERATION ........................................... 3-34
CHECKING THE REAR SUSPENSION ................................................... 3-34

PERIODIC MAINTENANCE
3-1
EAS2GC1074
PERIODIC MAINTENANCE
EAS2GC1075INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly ov erhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS2GC1076PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM
TIP
• From 4200 mi (7000 km) or 9 months, repeat the maintenance intervals starting from 1800 mi (3000 km) or 3 months.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL
ODOMETER READ-
INGS
600 mi (1000
km) or 1 month 1800 mi
(3000
km) or 3 months 3000 mi
(5000
km) or 6 months
1* Fuel line • Check fuel hoses for cracks or dam-
age.
• Replace if necessary. 
2Spark plug
• Check condition.
• Adjust gap and clean. 
3*Valve clear-
ance • Check and adjust valve clearance
when engine is cold. 
4*Air filter ele-
ment • Clean with solvent and apply Yamaha
foam air filter oil or other quality foam
air filter oil.
• Replace if necessary. 
5*
Breather
system • Check ventilation hose for cracks or
damage and drain any deposits. 
6*Fuel injec-
tion • Adjust engine idling speed.

7Exhaust sys-
tem• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.

8Engine oil
• Change (warm engine before drain-
ing). 
9Engine oil fil-
ter element•Replace.

10Engine oil
strainer• Clean.


PERIODIC MAINTENANCE
3-6
COOLING SYSTEMCheck coolant lev-
el and leakage
Check radiator cap
operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS
AND BOLTS
Retighten Refer to “STARTING AND
BREAK-IN” on page 1-28.
AIR FILTER
Clean and lubri-
cate Use Yamaha foam air filter oil
or other quality foam air filter
oil.
Replace
OIL FILTER
Replace
ENGINE GUARD Replace Breakage
FRAME Clean and inspect
FUEL TANK, FUEL
PUMP
Clean and inspect
FUEL HOSE Inspect
Replace Every four years
ITEM
After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks

PRE-OPERATION INSPECTION AND MAINTENANCE
3-9
EAS2GC1079
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAS2GC1080GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
Coolant Check that coolant is filled up to the radiator cap.
Check the cooling system for leakage. 3-10 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage. 1-28
Engine oil Check that the oil level is correct. Check the crank-
case and oil line for leakage. 3-16 – 18
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly. 3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary. 3-13 – 14
Brakes Check the play of front brake and effect of front and
rear brake. 3-25 – 31
Drive chain Check drive chain slack and alignment. Check that
the drive chain is lubricated properly. 3-31
5-69 – 70
Wheels Check for excessive wear and tire pressure. Check
for loose spokes and have no excessive play. 3-36 – 37
Steering Check that the handlebar can be turned smoothly and
have no excessive play. 3-37 – 38
Front forks and rear
shock absorber Check that they operate smoothly and there is no oil
leakage.
3-31 – 36
Cables (wires) Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and
has no cracks. 3-15 – 16
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is
not loose. 5-10 – 11
Lubrication Check for smooth operation. Lubricate if necessary. 3-14
3-38 – 39
Bolts and nuts Check the chassis and engine for loose bolts and
nuts. 1-32 – 33
Lead connectors Check that the AC magneto, ECU and ignition coil are
connected tightly. 1-9 – 12
Settings Is the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?
4-1 – 8

ENGINE
3-14
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1090LUBRICATING THE THROTTLE CABLE
1. Remove:• Cover (throttle cable cap) “1”
• Cover (grip cap) “2”
• Throttle grip cap “3”
2. Lubricate: • Throttle cable end “a”
3. Install: • Throttle grip cap
• Screw (throttle grip cap) 4. Install:
• Cover (grip cap)
• Cover (throttle cable cap)
EWA
WARNING
Check that the throttle grip moves smooth-
ly. If this does not move smoothly, correct
the installed positions.
EAS2GC1091CLEANING THE AIR FILTER ELEMENT
1. Remove:• Fuel tank cap cover “1”Refer to “FUEL TANK CAP” on page 1-20.
• Air filter case cover “2”
TIP
Loosen the quick fastener screw “3” and re-
move the air filter case cover.
2. Remove:
• Air filter mounting bolt “1”
• Air filter element “2”
• Air filter guide “3” (from the air filter element)
3. Wash: • Air filter element
EWA
WARNING
Do not use gasoline or organic (acid/alka-
line) volatile oil for washing.
TIP
After washing the element with air filter cleaner
or kerosene, squeeze and dry it completely.
ECA
Recommended lubricantLithium-soap-based grease
Screw (throttle grip cap) 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
1
2
b
a
T R..
1
2
3
3
3
13
2

ENGINE
3-15
NOTICE
Do not twist the element when squeezing
the element.
4. Check:• Air filter element
Damage  Replace.
5. Yamaha foam air filter oil or other quality foam air filter oil.
TIP
Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:• Air filter guide “1” (to the air filter element)
• Air filter element “2”
• Air filter mounting bolt “3”
7. Install: • Air filter case cover “1”
TIP
Align the air filter case cover groove “a” with the
air filter case edge “b”. 8. Install:
• Fuel tank cap cover
EAS2GC1092CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body jointRefer to “CHECKING THE THROTTLE
BODY JOINT” on page 8-10.
EAS2GC1093CHECKING THE BREATHER HOSES
1. Check:• Breather hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
ECA
NOTICE
Make sure the cylinder head breather hose
is routed correctly.
EAS2GC1094CHECKING THE EXHAUST SYSTEM
1. Remove:
• Exhaust pipe protector
2. Check: • Exhaust pipe 1
• Exhaust pipe 2
• SilencerCrack/damage  Replace.
Refer to “ENGINE REMOVAL” on page 6-1.
• Exhaust gas Leaks  Replace the gasket.
Refer to “ENGINE REMOVAL” on page 6-1.
Oil application quantify
50 g
Air filter mounting bolt 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
T R..
31
2
a
b
1
1