YAMAHA WR 450F 2016 Owners Manual

5
CHASSIS
GENERAL CHASSIS........................................................................................ 5-1
REMOVING THE LEFT SIDE COVER ....................................................... 5-3
REMOVING THE SEAT ............................................................................. 5-3
FRONT WHEEL ................................................................................................ 5-4
REMOVING THE FRONT WHEEL............................................................. 5-5
CHECKING THE FRONT WHEEL ............................................................. 5-5
DISASSEMBLING THE FRONT WHEEL ................................................... 5-6
ASSEMBLING THE FRONT WHEEL ......................................................... 5-6
INSTALLING THE FRONT WHEEL ........................................................... 5-7
REAR WHEEL .................................................................................................. 5-9
REMOVING THE REAR WHEEL ............................................................. 5-10
CHECKING THE REAR WHEEL.............................................................. 5-10
DISASSEMBLING THE REAR WHEEL ................................................... 5-10
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .......... 5-10
ASSEMBLING THE REAR WHEEL ......................................................... 5-11
INSTALLING THE REAR WHEEL............................................................ 5-11
FRONT BRAKE .............................................................................................. 5-13
INTRODUCTION ...................................................................................... 5-17
CHECKING THE FRONT BR AKE DISC .................................................. 5-17
REMOVING THE FRONT BRAKE CALIPER ........................................... 5-17
DISASSEMBLING THE FRONT BR AKE CALIPER................................. 5-17
CHECKING THE FRONT BR AKE CALIPER ........................................... 5-18
ASSEMBLING THE FRONT BR AKE CALIPER ....................................... 5-18
INSTALLING THE BRAKE CALIPER PISTON ........................................ 5-18
INSTALLING THE FRONT BR AKE CALIPER ......................................... 5-19
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................ 5-20
CHECKING THE FRONT BRAKE MASTER CYLINDER......................... 5-20
ASSEMBLING THE FRONT BRAKE M ASTER CYLINDER .................... 5-20
INSTALLING THE FRONT BRAKE MASTER CYLINDER....................... 5-21
REAR BRAKE ................................................................................................ 5-23
INTRODUCTION ...................................................................................... 5-27
CHECKING THE REAR BRAKE DISC............................. ........................ 5-27
REMOVING THE REAR BRAKE CALIPER ............................................. 5-28
DISASSEMBLING THE REAR BR AKE CALIPER ................................... 5-28
CHECKING THE REAR BRAKE CALIPER .............................................. 5-28
ASSEMBLING THE REAR BRAKE CALIPER ......................................... 5-28
INSTALLING THE BRAKE CALIPER PISTON ........................................ 5-29
INSTALLING THE REAR BRAKE CALIPER .................... ........................ 5-29
REMOVING THE REAR BRAKE MASTER CYLINDER .......................... 5-30
CHECKING THE REAR BRAKE MASTER CYLINDER ........................... 5-30
ASSEMBLING THE REAR BRAKE M ASTER CYLINDER....................... 5-30
INSTALLING THE REAR BRAKE MASTER CYLINDER ......................... 5-31

HANDLEBAR................................................................................................. 5-33
REMOVING THE HANDLEBAR ............................................................... 5-35
CHECKING THE HANDLEBAR ............................................................... 5-35
INSTALLING THE HANDLEBAR ............................................................. 5-35
FRONT FORK ................................................................................................. 5-40
REMOVING THE FRONT FORK LEGS ................................................... 5-42
DISASSEMBLING THE FRONT FO RK LEGS ......................................... 5-42
CHECKING THE FRONT FORK LEGS ................................................... 5-43
ASSEMBLING THE FRONT FORK LEGS ............................................... 5-44
INSTALLING THE FRONT FORK LEGS ................................................. 5-50
STEERING HEAD ........................................................................................... 5-53
REMOVING THE LOWER BRACKET...................................................... 5-55
CHECKING THE STEERING HEAD ........................................................ 5-55
INSTALLING THE STEERING HEAD ...................................................... 5-55
REAR SHOCK ABSORBER ASSEMBLY ..................................................... 5-58
HANDLING THE REAR SHOCK ABSORBER ......................................... 5-61
DISPOSING OF A REAR SH OCK ABSORBER ...................................... 5-61
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................... 5-61
REMOVING THE BEARING..................................................................... 5-61
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................... 5-62
CHECKING THE CONNECTING ARM AND RELAY ARM ...................... 5-62
INSTALLING THE RELAY ARM............................................................... 5-62
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY .................. 5-63
SWINGARM .................................................................................................... 5-65
REMOVING THE SWINGARM................................................................. 5-66
REMOVING THE BEARING..................................................................... 5-66
CHECKING THE SWINGARM ................................................................. 5-66
INSTALLING THE SWINGARM ............................................................... 5-67
CHAIN DRIVE ................................................................................................. 5-68
REMOVING THE DRIVE CHAIN.............................................................. 5-69
CHECKING THE DRIVE CHAIN .............................................................. 5-69
CHECKING THE DRIVE SPROCKET...................................................... 5-70
CHECKING THE REAR WHEEL SPROCKET ......................................... 5-70
INSTALLING THE DRIVE CHAIN ............................................................ 5-70

GENERAL CHASSIS
5-1
EAS2GC1150
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.
EAS2GC1151
GENERAL CHASSIS
Removing the seat and side cover
OrderPart name Q’tyRemarks
1 Seat 1
2 Air scoop (left) 1
3 Air scoop (right) 1
4 Side cover (left) 1
5 Side cover (right) 1
6 Rear fender 1
For installation, reverse the removal proce-
dure.
4
(2)
65
1
3
2
7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.
7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.
7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.
22 Nm (2.2 m kgf, 16 ft Ibf)T.R.
1.3 Nm (0.13 m kgf, 0.94 ft Ibf)T.R.16 Nm (1.6 m kgf, 12 ft Ibf)T.R.

GENERAL CHASSIS
5-2
Removing the headlight assembly and multi-function meter
OrderJob/Parts to remove Q’tyRemarks
1 Headlight body 1
2 Headlight coupler 1 Disconnect.
3 Headlight unit 1
4 Speed sensor coupler 1 Disconnect.
5 Multi-function meter coupler 2 Disconnect.
6 Multi-function meter optional switch coupler 1 Disconnect.
7 Indicator light coupler 1 Disconnect.
8 Multi-function meter 1
9 Meter bracket 1
For installation, reverse the removal proce-
dure.
4 (2)
6
7
8
9
5
1
3 2
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.3.8 Nm (0.38 m kgf, 2.8 ft Ibf)T.R.
3.8 Nm (0.38 m kgf, 2.8 ft Ibf)T.R.
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.
7 Nm (0.7 m kgf, 5.1 ft Ibf)T.R.

GENERAL CHASSIS
5-3
EAS2GC1152REMOVING THE LEFT SIDE COVER
1. Remove:• Bolt (side cover)
• Side cover “1”
TIP
Draw the left side cover “1” backward to re-
move it because its projection “a” is inserted in
the rear frame.
EAS2GC1153REMOVING THE SEAT
TIP
The fuel tank cap cover and the seat are cou-
pled with each other with a plastic band.
When removing the seat, always remove the
fuel tank cap cover beforehand.
1. Remove:• Fuel tank cap cover “1”
Refer to “FUEL TANK CAP” on page 1-20.
2. Remove: • Seat “1”
1
a
1
1
1

FRONT WHEEL
5-4
EAS2GC1154
FRONT WHEEL
Removing the front wheel
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
1 Front wheel axle pinch bolt 4 Loosen.
2 Front wheel axle nut 1
3 Front wheel axle 1
4 Front wheel 1
5 Speed sensor 1
6Collar 1
7 Oil seal 1
8 Bearing 2
9 Brake disc 1
For installation, reverse the removal proce-
dure.
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
New
LT
LS
LS
LS
8
7
8
(6)
9
1 2
1
3
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
4
90 Nm (9.0 m kgf, 65 ft lbf)T.R.
5
6

FRONT WHEEL
5-5
EAS2GC1155REMOVING THE FRONT WHEEL
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:• Front wheel
EAS2GC1156CHECKING THE FRONT WHEEL
1. Check:• Front wheel axleRoll the front wheel axle on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
•Tire(s)
• Front wheelDamage/wear  Replace.
Refer to “CHECKING THE TIRES” on page
3-36 and “CHECKING THE WHEELS” on
page 3-37.
3. Check: • Spokes
Bend/damage  Replace.
Loose  Tighten.
Tap the spokes with a screwdriver.
TIP
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
4. Tighten: • Spokes
Refer to “CHECKING AND TIGHTENING
THE SPOKES” on page 3-36.
TIP
After tightening the spokes, measure the wheel
runout.
5. Measure:• Wheel radial runout “a”
• Wheel lateral runout “b”Out of specification  Repair/replace.
6. Check: •CollarsDamage/wear  Replace.
7. Check: • BearingFront wheel turns roughly or is loose  Re-
place the wheel bearings.
• Oil seals Damage/wear  Replace.
Spokes
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
T R..
a b

FRONT WHEEL
5-6
EAS2GC1157DISASSEMBLING THE FRONT WHEEL
1. Remove:• Oil seals
• Bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel sur-
face.
c. Remove the bearings with a bearing puller.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1158ASSEMBLING THE FRONT WHEEL
1. Install:• Bearing (left side) “1”
• Spacer “2”
• Bearing (right side) “3”
• Oil seal “4”
TIP
• Apply the lithium-soap-based grease to the bearing and the oil seal lip when installing.
• Left side of bearing shall be installed first.
• Install the oil seal with its manufacture’s
marks or numbers facing outward.
ECA
NOTICE
Install the bearing by pressing its outer race
parallel.
TIP
Use a socket “1” that matches the diameter of
the bearing outer race and that of the oil seal.
2. Install: • Brake disc “1”
• Brake disc bolt “2”
TIP
Tighten the bolts in stages and in a crisscross
pattern.
1 2
New
Brake disc bolt
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
LOCTITE®
3
2
14
New
1
T R..

FRONT WHEEL
5-7
3. Install:• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
4. Install:
• Speed sensor “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip of speed sensor.
Make sure the two projections “a” in the wheel
hub are meshed with the two slots “b” in the
speed sensor.
EAS2GC1159INSTALLING THE FRONT WHEEL
1. Install:• Front wheel
TIP
Install the brake disc “1” between the brake
pads “2” correctly. 2. Install:
• Front wheel axle “1”
TIP
Apply the lithium-soap-based grease to the
front wheel axle.
3. Tighten:
• Front wheel axle nut “1”
ECA
NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:• Front wheel axle pinch bolt “1”1
a b
LS
Front wheel axle nut
90 Nm (9.0 m·kgf, 65 ft·lbf)
Front wheel axle pinch bolt 21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
1
T R..

FRONT WHEEL
5-8
1
1