maintenance YAMAHA WR 450F 2016 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2016, Model line: WR 450F, Model: YAMAHA WR 450F 2016Pages: 426, PDF Size: 10.86 MB
Page 6 of 426
EAS2GC1003
INTRODUCTION
Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yama-
ha's vast experience in the production of pacesetting racing machines. It represents the highest
grade of craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you
have any questions about this manual or your machine, please contact your Yamaha dealer.
The design and manufacture of this Yamaha machine fully comply with the emissions standards for
clean air applicable at the date of manufacture. Yamaha has met these standards without reducing
the performance or economy of operation of the machine. To maintain these high standards, it is im-
portant that you and your Yamaha dealer pay close attention to the recommended maintenance
schedules and operating instructions contained within this manual.
TIP
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor
discrepancies between your machine and this ma nual. If you have any questions concerning this
manual, please consult your Yamaha dealer.
EWA
WARNING
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-
TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EAS2GC1004
IMPORTANT MANUAL INFORMATION
Particularly important informat ion is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
Page 14 of 426
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
Page 42 of 426
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
Page 44 of 426
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.
Page 45 of 426
MAINTENANCE AFTER BREAK-IN
1-31
EAS2GC1055
MAINTENANCE AFTER BREAK-IN
After a break-in, perform careful maintenance
to get ready for the next practice or race.
Refer to “PRE-OPERATION INSPECTION
AND MAINTENANCE” on page 3-9.
EAS2GC1056MAJOR MAINTENANCE
1. For the engine• Leaks around the engineCheck for pressure l eaks from the cylinder
head or the cylinder, oil leaks from the
crankcase or the case cover, leaks from the
coolant system, and other leaks.
• Check that the valve, the cylinder head, the cylinder, the piston, and the piston ring fit
one another, and that contact between the
valve and the cylinder head, and that be-
tween the cylinder and the piston are cor-
rect.
• Engine oil change Drain the oil, and check for dirt and foreign
materials such as metal chips. (If any foreign
material is mixed, disassemble and check
the crankcase.)
Pour the specified amount of the recom-
mended oil.
• AC magneto
Check for looseness in mounted areas of
the rotor and the stator.
Check that the connector is not being dis-
connected.
• Silencer Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel (s) Check the wheel for runout. Check the
spoke for looseness.
• Brake(s) Check the brake disc mounting bolt for
looseness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks. • Cable
Grease and adjust cables.
•Drive chain
Lubricate the drive chain and adjust its ten-
sion.
• Fuel tank
Clean the inside of the fuel tank. Check for
leaks.
• Suspension
Check for oil leaks in the front fork or the rear
shock absorber. Check that the mounted
conditions are good.
• Sprocket Check for looseness in the sprocket mount-
ed on the rear wheel.
• Mounting bolts and nuts
Check mounted areas for looseness.
ECA
NOTICE
After a break-in or before 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.)
• Greasing and oilingAlways grease or oil the specified points.
Page 97 of 426
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
Page 99 of 426
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.
Page 100 of 426
PERIODIC MAINTENANCE
3-2
EAS2GC1077GENERAL MAINTENANCE AND LUBRICATION CHARTNO. 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
1Clutch • Check operation.
• Adjust or replace cable.
2*Cooling sys-
tem • Check hoses for cracks of damage.
• Replace if necessary.
• Replace with ethylene glycol anti- freeze coolant every 1 year. Every 1 year
3*Spark arrest-
er • Clean.
4*Front brake • Check operation, fluid level, and for flu-
id leakage.
• Replace brake pads if necessary.
• Replace brake fluid every 1 year. Every 1 year
5* Rear brake • Check operation, fluid level, and for flu-
id leakage.
• Replace brake pads if necessary.
• Replace brake fluid every 1 year. Every 1 year
6* Brake hoses • Check for cracks or damage.
• Replace. Every 4 years
7*Wheels • Check runout, spoke tightness and for
damage.
• Tighten spokes if necessary.
8*
Tires • Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
9*
Wheel bear-
ings • Check bearings for smooth operation.
• Replace if necessary.
10*Swingarm
pivot bear-
ings • Check bearing assemblies for loose-
ness.
• Moderately repack with lithium-soap- based grease.
11Drive chain• Check chain slack/alignment and con-
dition.
• Adjust and lubricate chain with a spe- cial O-ring chain lubricant thoroughly. Every ride
12*
Steering
bearings • Check bearing assemblies for loose-
ness.
• Moderately repack with lithium-soap- based grease every 1200 mi (2000
km) or 12 months (whichever comes
first).
Page 101 of 426
PERIODIC MAINTENANCE
3-3
TIP
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and f ill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
13
Brake and
clutch lever
pivot shafts • Apply lithium-soap-based grease (all-
purpose grease) lightly.
14Brake pedal
pivot shafts• Apply lithium-soap-based grease (all-
purpose grease) lightly.
15Sidestand
pivot• Check operation.
• Apply lithium-soap-based grease (all-
purpose grease) lightly.
16*
Front fork • Check operation and for oil leakage.
• Replace if necessary.
17*Shock ab-
sorber as-
sembly • Check operation and for oil leakage.
• Replace if necessary.
18*Rear sus-
pension link
pivots • Apply molybdenum disulfide grease
lightly.
19*Control ca-
bles • Apply Yamaha chain and cable lube or
engine oil 10W-30 thoroughly.
20*Throttle grip
housing and
cable • Check operation and free play.
• Adjust the throttle cable free play if
necessary.
• Lubricate the throttle grip housing and cable.
21*
Chassis fas-
teners • Check all chassis fitting and fasteners.
• Correct if necessary.
22Battery• Check terminal for looseness and cor-
rosion.
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
Page 102 of 426
PERIODIC MAINTENANCE
3-4
EAS2GC1078MAINTENANCE INTERVALS FOR COMPETITION USE
TIP
• The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the re-
quired maintenance and lubrication intervals. If you ar e a doubt as to what intervals to follow in
maintaining and lubricating your ma chine, consult your Yamaha dealer.
• Periodic inspection is essential in making full use of the machine performance. The service life of
the parts varies substantially according to the en vironment in which the machine runs (e.g., rain,
dirt, etc.). Therefore, earlier inspection is required by reference to the list below.
ITEM After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks
ENGINE OIL Replace
VALVES Check the valve
clearances The engine must be cold.
Inspect Check the valve seats and
valve stems for wear.
Replace
VALVE SPRINGS Inspect Check the free length and the
tilt.
Replace
VALVE LIFTERS Inspect Check for scratches and wear.
Replace
CAMSHAFTS Inspect the camshaft surface.
Inspect Inspect the decompression
system.
Replace
CAMSHAFT
SPROCKETS Inspect Check for wear on the teeth
and for damage.
Replace
PISTON Inspect crack.
Inspect Inspect carbon deposits and
eliminate them.
Clean
Replace It is recommended that the pis-
ton pin and ring are also re-
placed at the same time.
PISTON RING
Inspect Check ring end gap.
Replace