check engine YAMAHA WR 450F 2016 Owners Manual

EAS2GC1005
SAFETY INFORMATION
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine to be operat ed on any public street, road, or highway. Off-road
use on public lands may also be illegal. Pl ease check local regulations before riding.
• THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its char-
acteristics.
• THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine.
• ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield. Also
wear heavy boots, gloves, and protective clothing. Al ways wear proper fitting clothing that will not
be caught in any of the moving parts or controls of the machine.
• ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-oper-
ation checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or ex-
haust system. Never refuel in the vicini ty of an open flame, or while smoking.
• GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get
into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, imme-
diately wash skin areas with soap and water, and change your clothes.
• ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are
poisonous. These fumes contain carbon monoxide, whic h by itself is odorless and colorless. Car-
bon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope
or soft ground as it may fall over.
• THE ENGINE, EXHAUST PIPE AND MUFFLER WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT. For safety, drain the gasoline from the fuel tank before transporting the vehicle.

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TABLE OF CONTENS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
TUNING
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING

MULTI-FUNCTION DISPLAY......................................................................... 1-21
DESCRIPTION ......................................................................................... 1-21
BASIC MODE ........................................................................................... 1-21
CHANGEOVER TO BASIC MODE /RACE MODE.................................... 1-22
RACE MODE ............................................................................................ 1-23
FUNCTION DIAGRAM ............................................................................. 1-26
STARTING AND BREAK-IN .......................................................................... 1-28
FUEL ........................................................................................................ 1-28
HANDLING NOTE .................................................................................... 1-28
AIR FILTER MAINTENANCE ................................................................... 1-28
STARTING A COLD ENGINE .................................................................. 1-28
STARTING A WARM ENGINE ................................................................. 1-30
BREAK-IN PROCEDURES .... .................................................................. 1-30
MAINTENANCE AFTER BREAK-IN .............................................................. 1-31
MAJOR MAINTENANCE .......................................................................... 1-31
TORQUE-CHECK POINTS ............................................................................ 1-32
MOTORCYCLE CARE AND STORAGE ........................................................ 1-34
CARE........................................................................................................ 1-34
STORAGE ................................................................................................ 1-35

DESCRIPTION
1-4
EAS2GC1009
DESCRIPTION
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have pur-
chased.1. Clutch lever 12. Headlight
2. Multi-function display 13. Radiator
3. Front brake lever 14. Coolant drain bolt
4. Throttle grip 15. Rear brake pedal
5. Start switch 16. Air filter
6. Radiator cap 17. Drive chain
7. Fuel tank cap 18. Shift pedal
8. Engine stop switch 19. Oil level check window
9. Taillight 20. Starter knob/idle screw
10. Fuel tank 21. Front fork
11. Kickstarter lever
32
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10
91 112 1376
54
15 14 21 20 19 18 17 16

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.

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

SPECIAL TOOLS
1-17
Valve spring compressor at-
tachment
90890-04108
Valve spring compressor
adapter 22 mm
YM-04108This tool is used to discon-
nect or connect the valve and
the valve spring.
Rotor puller
90890-04142
Rotor puller
YM-04142 This tool is used to remove
the rotor.
Crankcase separating tool
90890-04152
Crankcase separating tool
YU-A9642 This tool is used to remove
the crankshaft.
Ignition checker
90890-06754
Oppama pet–4000 spark
checker
YM-34487 This tool is used to check the
spark performance of the ig-
nition coil.
Digital tachometer
90890-06760
Digital tachometer
YU-39951-B This tool is used to measure
the engine speed.
Yamaha bond No. 1215
90890-85505
(Three bond No.1215®) This sealant (Bond) is used
for crankcase mating sur-
face, etc.
Tool name/Part number How to use Illustration

CONTROL FUNCTIONS
1-18
EAS2GC1029
CONTROL FUNCTIONS
EAS2GC1030INDICATOR LIGHTS AND WARNING
LIGHTS
Fuel level warning light “ ”
This warning light comes on when the fuel level
drops below approximately 1.6 L (0.42 US gal,
0.35 Imp.gal). When this occurs, refuel as soon
as possible.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the start switch is pushed, or if the warn-
ing light remains on, have a Yamaha dealer
check the electrical circuit.
Engine trouble warning light “ ”
This warning light comes on or flashes if a prob-
lem is detected in the electrical circuit monitor-
ing the engine. If this occurs, have a Yamaha
dealer check the vehicle.
The electrical circuit of the warning light can be
checked by pushing the start switch. The warn-
ing light should come on for a few seconds, and
then go off.
If the warning light does not come on initially
when the start switch is pushed, or if the warn-
ing light remains on, have a Yamaha dealer
check the electrical circuit.
EAS2GC1031ENGINE STOP SWITCH
The engine stop switch “1” is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
After the engine stops, the multi-function dis-
play will go off and the power supply to the ECU
(Electronic Control Unit) will be cut off if the en-
gine stop switch is pushed and held.
TIP
The multi-function display will go off after one
minute if the engine stop switch is not pushed.
EAS2GC1032START SWITCH
The start switch “1” is located on the right han-
dlebar. Push this switch to crank the engine
with the starter.
EAS2GC1033CLUTCH LEVER
The clutch lever “1” is located on the left han-
dlebar. The clutch lever disengages or engag-
es the clutch.
Pull the clutch lever toward the handlebar to
disengage the clutch, and release the lever to
engage the clutch.
1. Engine trouble warning light “ ”
2. Fuel level warning light “ ”
12

STARTING AND BREAK-IN
1-28
EAS2GC1048
STARTING AND BREAK-IN
EAS2GC1049FUEL
Always use the recommended fuel as stated
below. Also, be sure to use new gasoline the
day of a race.
ECA
NOTICE
Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to the engine internal parts such as valves,
piston rings, and exhaust system, etc.
TIP
Your Yamaha engine has been designed to use
premium unleaded gasoline with a pump oc-
tane number [(R+M)/2] of 91 or higher, or a re-
search octane number of 95 or higher. If
knocking (or pinging) occurs, use a gasoline of
a different brand.
EWA
WARNING
• For refueling, be sure to stop the engine and use enough care not to spill any fuel.
Also be sure to avoid refueling close to a
fire.
• Refuel after the engine, exhaust pipe, etc.
have cooled off.
Gasohol (For USA and Canada)
There are two types of gasohol: gasohol con-
taining ethanol and that containing methanol.
Gasohol containing ethanol can be used if the
ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by
Yamaha because it can cause damage to the
fuel system or vehicle performance problems.
EAS2GC1050HANDLING NOTEEWA
WARNING
Never start or run the engine in a closed ar-
ea. The exhaust fumes are poisonous; they
can cause loss of consciousness and death
in a very short time. Always operate the ma-
chine in a well-ventilated area.
ECA
NOTICE
• Unlike a two-stroke engine, this engine cannot be kick started when the throttle is
open because the kickstarter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the engine
to start.
• Before starting the machine, perform the
checks in the pre-operation check list.
EAS2GC1051AIR FILTER MAINTENANCE
According to “CLEANING THE AIR FILTER
ELEMENT” section in the CHAPTER 3, apply
the Yamaha foam air filter oil or other quality
foam air filter oil to the element. (Excess oil in
the element may adversely affect engine start-
ing.)
EAS2GC1052STARTING A COLD ENGINEECA
NOTICE
For maximum engine life, never accelerate
hard when the engine is cold!
In order for the ignition circuit cut-off system to
enable starting, one of the following conditions
must be met:
• The transmission is in the neutral position.
• The transmission is in gear with the clutch le- ver pulled.
1. Pull the starter knob/idle screw “1” to its full length.
TIP
When the ambient temperature is 15°C (59°F)
or below, use the starter knob/idle screw.
2. Completely close the throttle.
3. Start the engine by pushing the start switch.If the engine fails to start when using the
start switch, release it, wait a few seconds,
and then try again.
Each starting attempt should be as short as
possible to preserve the battery. Do not
crank the engine more than 10 seconds on
any one attempt. If the engine does not start
with the starter motor, try using the kickstart-
er.
Recommended fuel
Premium unleaded gasoline
only
Fuel tank capacity 7.5 L (2.0 US gal, 1.7 lmp.gal)
Fuel reserve amount 2.0 L (0.5 US gal, 0.4 Imp.gal)
1

STARTING AND BREAK-IN
1-30
EAS2GC1053STARTING A WARM ENGINE
Follow the same procedure as for starting a
cold engine with the exception that the starter is
not required when the engine is warm.
TIP
If it fails to start, fully open the throttle grip and
give 10 to 20 slow kicks to clear the engine of
the rich air-fuel mixture retained in it.
EAS2GC1054BREAK-IN PROCEDURES
A break-in is important so that rotating portion,
sliding surfaces, and mounted areas may fit
one another, and that the rider may become ac-
customed to the machine.
ECA
NOTICE
Before running, do maintenance on the air
filter element.
Refer to “CLEANING THE AIR FILTER ELE-
MENT” on page 3-14.
1. After warming up the engine, drive it for about 20 minutes at a throttle opening of 1/2
or less.
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.
2. Make a pit stop, and check mounted areas
for looseness, oil leaks, or other problems.
3. Then, drive it for about 40 minutes at a throt- tle opening of 3/4 or less.
4. Make a pit stop again, and thoroughly check mounted areas for looseness, oil leaks, or
other problems. Thorough checks and ad-
justments are required in particular for
stretch of cables, free play of the brake,
stretch of the drive chain, looseness of the
spoke, and so on.
ECA
NOTICE
After a break-in or after each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them. (Refer to “TORQUE-CHECK
POINTS” on page 1-32.)
Also when the following parts are replaced,
a break-in is required.
• Cylinder and Crankshaft: A break-in is re-quired for about an hour.
• Piston, Piston ring, Valve, Camshaft, and
Gear: A break-in is required for about 30
minutes at a throttle opening of 1/2 or less.
Observe the condition of the engine careful-
ly during a break-in.
For checkpoints for a break-in, see “MAIN-
TENANCE AFTER BREAK-IN”. If any prob-
lem is found, immediately stop the engine
and make a checkup.