YAMAHA WR 450F 2016 Owners Manual

REAR SHOCK ABSORBER ASSEMBLY
5-59
12 Collars2
13 O-ring 2
14 Dust seal 2
15 Stopper ring 1
16 Bearing 1
For installation, reverse the removal proce-
dure.
Removing the rear shock absorber assembly
Order Part name Q’tyRemarks
2
12
1615
14 13
12
14
4
5
7
6
8 3
9
9
10
10
11
1
New
New
13New
LS
LS
M
M
M
M
M

REAR SHOCK ABSORBER ASSEMBLY
5-60
Disassembling the relay arm
OrderPart name Q’tyRemarks
1 Relay arm 1
2 Connecting arm 1
3Collars 3
4Oil seals 6
5Washers 8
6 Bearing 6
For assembly, reverse the disassemble pro-
cedure.
5
3
5
6
165
4
5
5
4
56
6
5
4
3
2
4
6
6
3
4
4
T.R.80 Nm (8.0 mlbf)
kgf, 58 ft
M
M
M
M
M
M M

REAR SHOCK ABSORBER ASSEMBLY
5-61
EAS2GC1208HANDLING THE REAR SHOCK ABSORBEREWA
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure that you understand the following in-
formation. The manufacturer cannot be held
responsible for property damage or person-
al injury that may result from improper han-
dling of the rear shock absorber.
• Do not tamper or attempt to open the rear shock absorber.
• Do not subject the rear shock absorber to an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.
EAS2GC1209DISPOSING OF A REAR SHOCK ABSORB-
ER
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA
WARNING
• Wear protective glasses to prevent your
eyes from damage due to possible gas or
metal chips scattered.
• To dispose of a damaged or a worn-out rear shock absorber, take the unit to your
Yamaha dealer for this disposal proce-
dure.
EAS2GC1210REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:• Rear shock absorber assembly lower bolt
“1”
TIP
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly
EAS2GC1211REMOVING THE BEARING
1. Remove:• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer
race and remove the stopper ring.
1
1

REAR SHOCK ABSORBER ASSEMBLY
5-62
2. Remove:• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1212CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
•Spring
Damage/wear  Replace. • Spring guide
Damage/wear  Replace.
• Bearing
Damage/wear  Replace.
•Bolts Bends/damage/wear  Replace.
EAS2GC1213CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
2. Check: • Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check: • Oil sealsDamage/pitting  Replace.
EAS2GC1214INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install: • Bearing “1”
• Washer “2”
• Oil seals “3” (to relay arm “4”)
1
Recommended lubricantMolybdenum disulfide grease
Installed depth “a” 0 mm (0 in)
New
3
3
43
2 2
2 2
a
1 1 1

REAR SHOCK ABSORBER ASSEMBLY
5-63
3. Install:• Bearing “1”
• Oil seals “2” (to connecting arm “3”)
EAS2GC1215INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY
1. Lubricate:• Bearing (lower side)
•Dust seal
•Collars
• Bushing
ECA
NOTICE
Do not apply the grease to the bearing outer
race because it will wear the rear shock ab-
sorber surface on which the bearing is
press fitted.
2. Lubricate:• O-ring
3. Install: • Bearing
• Stopper ring (to rear shock absorber assembly (upper
side))
TIP
• Install the bearing parallel until the stopper ring groove appears by pressing its outer
race.
• After installing the stopper ring, push back the
bearing unit it contacts the stopper ring. 4. Install:
• Bearing “1”
• Bushing “2”
• Collar “3”
• Dust seal “4”(to rear shock absorber assembly (lower
side))
TIP
Install the dust seals with their lips facing in-
ward.
5. Lubricate:
• Connecting arm and frame bolt
• Relay arm and connecting arm bolt
• Relay arm and swingarm bolt(circumference and threaded portion)
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly lower bolt
6. Install: • Rear shock absorber assembly
TIP
• When installing the rear shock absorber as-sembly, lift up the swingarm.
• Install the rear shock absorber assembly up- per bolt, and connecting arm bolt (frame side)
from the right.
• Install the rear shock absorber assembly low- er bolts, connecting arm bolt (relay arm side),
and relay arm bolt (swingarm side) from the
left.
Installed depth “a”
0 mm (0 in)
Recommended lubricant Molybdenum disulfide grease
Recommended lubricant Lithium-soap-based grease
New
3
a
1
1 2
a
2
New
Installed depth “a” 4.25 mm (0.17 in)
Recommended lubricant Molybdenum disulfide grease

REAR SHOCK ABSORBER ASSEMBLY
5-64
7. Tighten:• Rear shock absorber assembly upper bolt
• Connecting arm bolt (frame side)
• Connecting arm bolt (relay arm side)
• Relay arm bolt (swingarm side)
• Rear shock absorber assembly lower bolt Rear shock absorber assembly
upper bolt
56 Nm (5.6 m·kgf, 41 ft·lbf)
Connecting arm bolt (frame side) 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (relay arm
side) 80 Nm (8.0 m·kgf, 58 ft·lbf)
Relay arm bolt (swingarm side) 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear shock absorber assembly
lower bolt 53 Nm (5.3 m·kgf, 38 ft·lbf)
T R..
T R..
T R..
T R..
T R..

SWINGARM
5-65
EAS2GC1216
SWINGARM
Removing the swingarm
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Brake hose holder Refer to “REAR BRAKE” on page 5-23.
Rear brake caliper Refer to “REAR BRAKE” on page 5-23.
Bolt (brake pedal)
Drive chain
1 Collars
2
2 Oil seals
2
3 Thrust bearing
2
4 Bushing
2
5 Oil seals
2
6 Bearing
4
For installation, reverse the removal proce-
dure.
1
2
3
6
4
6
4
1
3
6
2
5
T.R.70 Nm (7.0 mlbf)
kgf, 51 ft
T.R.4.0 Nm (0.40 mlbf)
kgf, 2.9 ft

SWINGARM
5-66
EAS2GC1217REMOVING THE SWINGARM
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Measure:• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the pivot shaft nut.
b. Measure the swingarm side play “a” by mov- ing the swingarm from side to side.
c. If the swingarm side play is out of specifica- tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b” by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1218REMOVING THE BEARING
1. Remove:• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1219CHECKING THE SWINGARM
1. Check:• Swingarm
Bends/cracks/damage  Replace.
2. Check: • Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check: • Oil seals
Damage  Replace.
• Bearing
• Spacers Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set.
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial) 1.0 mm (0.04 in)
T R..

SWINGARM
5-67
EAS2GC1220INSTALLING THE SWINGARM
1. Lubricate:• Bearing
•Collars
• Spacers
• Oil seal
• Pivot shaft
2. Install: • Bearing “1”
• Oil seals “2” (to the swingarm)
TIP
First install the outer and then the inner bear-
ings to a specified depth from inside.
3. Install:
• Swingarm
TIP
Install the pivot shaft from the right.
4. Install:• Rear wheelRefer to “REAR WHEEL” on page 5-9.
5. Adjust:
• Drive chain slackRefer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-31. Recommended lubricant
Molybdenum disulfide grease
Installed depth “a” 0–0.5 mm (0–0.02 in)
Installed depth “b” 6.5 mm (0.26 in)
Pivot shaft nut 85 Nm (8.5 m·kgf, 61 ft·lbf)
Drive chain slack (on a suitable
stand) 50.0–60.0 mm (1.97–2.36 in)
New
New
2
22
1
1
aaa
b
ba
NewNewNew
T R..

CHAIN DRIVE
5-68
EAS2GC1221
CHAIN DRIVE
Removing the drive chain
Job OrderPart name Q’tyServicing Information
Drive sprocket Refer to “ENGINE REMOVAL” on page 6-1.
1 Drive chain 1
For installation, reverse the removal proce-
dure.
1
T.R.75 Nm (7.5 mlbf)
kgf, 54 ft
T.R.7 Nm (0.7 mlbf)
kgf, 5.1 ft