YAMAHA WR 450F 2016 Owners Manual

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
6-74
EAS2GC1317
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
Removing the crankshaft assembly and balancer shaft
Order Part name Q’tyRemarks
Crankcase Separate.
Refer to “CRANKCASE” on page 6-69.
Transmission Refer to “TRANSMISSION” on page 6-77.
1 Balancer shaft 1
2 Crankshaft assembly 1
For installation, reverse the removal proce-
dure.
1
2

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
6-75
EAS2GC1318REMOVING THE BALANCER SHAFT
1. Remove:• Balancer shaft “1”
TIP
Remove the balancer shaft with its flat side “a”
facing the crankshaft.
EAS2GC1319REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:• Crankshaft assembly “1”
TIP
Remove the crankshaft assembly by using the
crankcase separating tool “2”.
EAS2GC1320CHECKING THE CRANKSHAFT ASSEMBLY
1. Measure:• Crankshaft runoutOut of specification  Replace the crank-
shaft, bearing or both.
TIP
Turn the crankshaft slowly.
2. Measure: • Big end side clearance “a”Out of specification  Replace the big end
bearing, crankshaft pin, or connecting rod.
3. Measure: • Crank assembly width “a”Out of specification  Replace the crank-
shaft.
Crankcase separating tool
90890-04152
YU-A9642
1
a
2
1
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.150–0.450 mm (0.0059–0.0177
in)
Crank assembly width 61.93–62.00 mm (2.438–2.441 in)

CRANKSHAFT ASSEMBLY AND BALANCER SHAFT
6-76
4. Check:• Crankshaft sprocket “1”
Damage  Replace the crankshaft.
5. Check: • Crankshaft journal oil passageObstruction  Blow out with compressed
air.
EAS2GC1321INSTALLING THE CRANKSHAFT ASSEM-
BLY
1. Install: • Crankshaft assembly
TIP
Install the crankshaft assembly with the crank-
shaft installer pot “1”, crankshaft installer bolt
“2”, adapter (M12) “3” and spacer “4”.
ECA
NOTICE
• To avoid scratching the crankshaft and to ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease.
• In order to prevent the crankshaft seizure,
apply molybdenum disulfide grease.
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft as-
sembly bottoms against the bearing.
Crankshaft installer pot 90890-01274
Installing pot YU-90058
Crankshaft installer bolt 90890-01275
Bolt YU-90060
Adapter (M12) 90890-01278
Adapter #3 YU-90063
Spacer (crankshaft installer) 90890-04081
Pot spacer YM-91044
1

TRANSMISSION
6-77
EAS2GC1322
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
OrderPart name Q’tyRemarks
Engine Refer to “ENGINE REMOVAL” on page 6-1.
Crankcase Separate.
Refer to “CRANKCASE” on page 6-69.
1 Main axle 1
2 Drive axle 1
3 Long shift fork guide bar 1
4 Short shift fork guide bar 1
5Spring 4
6 Shift cam 1
7 Shift fork 3 (R) 1
8 Shift fork 2 (C) 1
9 Shift fork 1 (L) 1
10 Collar 1
For installation, reverse the removal proce-
dure.
2
10
1 5 3
4
5
7
8
69
M
M
M
M
M
EE
E
E
LS
New

TRANSMISSION
6-78
EAS2GC1323REMOVING THE TRANSMISSION
1. Remove:• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Shift cam “3”
• Shift fork 3 “4”
• Shift fork 2 “5”
• Shift fork 1 “6”
• Main axle “7”
• Drive axle “8”
• Collar “9”
TIP
• Remove assembly with the collar “9” installed to the crankcase.
• Make a note of the position of each part. Pay particular attention to the location and direc-
tion of shift forks.
• Remove the main axle and the drive axle all together by tapping the drive axle lightly with
a soft hammer.
EAS2GC1324CHECKING THE SHIFT FORKS
1. Check:• Shift fork cam follower “1”
• Shift fork pawl “2”Bends/damage/scoring/wear  Replace the
shift fork.
2. Check: • Shift fork guide barRoll the shift fork guide bar on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement  Replace the shift forks
and shift fork guide bar as a set.
1
4 6 2
53
8
7
9

TRANSMISSION
6-79
EAS2GC1325CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:• Shift drum grooveDamage/scratches/wear  Replace the
shift drum assembly.
• Shift drum segment “1” Damage/wear  Replace the shift drum as-
sembly.
EAS2GC1326CHECKING THE TRANSMISSION
1. Measure: • Main axle runout(with a centering device and dial gauge “1”)
Out of specification  Replace the main ax-
le.
2. Measure: • Drive axle runout(with a centering device and dial gauge “1”)
Out of specification  Replace the drive ax-
le. 3. Check:
• Transmission gears
Blue discoloration/pitting/wear  Replace
the defective gear (s).
• Transmission gear dogs
Cracks/damage/rounded edges  Replace
the defective gear (s).
4. Check:
• Transmission gear movementRough movement  Replace the defective
gear (s).
EAS2GC1327INSTALLING THE TRANSMISSION
1. Install:
• 5th pinion gear (25T) “1”
• 3rd pinion gear (16T) “2”
• Collar “3”
• 4th pinion gear (20T) “4”
• 2nd pinion gear (15T) “5”(to the main axle “6”)
TIP
Before installation, apply molybdenum disulfide
oil to the inner and end surface of the idler gear
and to the inner surface of the sliding gear, then
install.
Main axle runout limit
0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
3 4
2
1
6
5
M

TRANSMISSION
6-80
2. Install:• Collar “1”
• 2nd wheel gear (26T) “2”
• 4th wheel gear (21T) “3”
• 3rd wheel gear (21T) “4”
• 5th wheel gear (21T) “5”
• Collar “6”
• 1st wheel gear (29T) “7”
• O-rings “8” (to the drive axle “9”)
TIP
• Before installation, apply molybdenum disul-fide oil to the inner and end surface of the idler
gear and the collar and to the inner surface of
the sliding gear, then install.
• Apply the lithium-soap-based grease on the
O-ring.
3. Install: • Washer “1”
• Circlip “2”
TIP
• Be sure the circlip sharp-edged corner “a” is positioned opposite side to the washer and
gear “b”.
• Install the circlip with its ends “c” settled even-
ly on the spline crests. 4. Install:
• Collar “1”
TIP
• Apply the lithium-soap-based grease on the oil seal lip.
• When installing the collar into the crankcase, pay careful attention to the crankcase oil seal
lip.
5. Install: • Main axle “1”
• Drive axle “2”
TIP
• Install to the left crankcase simultaneously.
• Apply engine oil to the main axle and the drive
axle bearing.
New
2 9
8
3
4
5
6
7
New
MM
LS
M
1
New
2 1
2
ab
cc
1
2
EE

TRANSMISSION
6-81
6. Install:• Shift fork 1 (L) “1”
• Shift fork 2 (C) “2”
• Shift fork 3 (R) “3”
• Shift cam “4”(to the main axle and the drive axle)
TIP
• Apply engine oil to the shift fork grooves.
• Apply engine oil to the shift cam groove and
the bearing contact surface.
• Mesh the shift fork 1 (L) with the 4th wheel gear “5” and shift fork 3 (R) with the 5th wheel
gear “7” on the drive axle.
• Mesh the shift fork 2 (C) with the 3rd pinion
gear “6” on the main axle. 7. Install:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Spring “3”
TIP
• Screw the spring into the shift fork guide bar lightly beforehand.
• Apply the engine oil on the shift fork guide
bars.
8. Check: • Operation of shift cam and shift fork
• Transmission operationUnsmooth operation  Repair.
3
12
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E
2
1 3
E

7
COOLING SYSTEM
RADIATOR....................................................................................................... 7-1
HANDLING NOTE ...................................................................................... 7-3
CHECKING THE RADIATOR ..................................................................... 7-3
WATER PUMP .................................................................................................. 7-4
REMOVING THE OIL SEAL ....................................................................... 7-5
CHECKING THE WATER PUMP ............................................................... 7-5
CHECKING THE BEARING ....................................................................... 7-5
INSTALLING THE OIL SEAL ..................................................................... 7-5
ASSEMBLING THE WATER PUMP........................................................... 7-5

RADIATOR
7-1
EAS2GC1328
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, serv ice engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS2GC1329
RADIATOR
Removing the radiator
OrderPart name Q’tyRemarks
Coolant Drain.
Refer to “CHANGING THE COOLANT” on
page 3-10.
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
Air filter case Refer to “THROTTLE BODY” on page 8-7.
1 Radiator guard 2
2 Radiator hose clamp 8 Loosen.
3 Radiator fan 1
12
13
New
New
New
LS
LS
3
4 58 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
6
7
8 9
10
11 2
2
2
2
2
2
2
1
1