YAMAHA YZ450F 2016 Owners Manual

CHASSIS
3-27
f. Loosen the bleed screw and push the brake
caliper piston in.
EWA
WARNING
Do not reuse the drained brake fluid.
g. Tighten the bleed screw.
h. Install the brake pad “10” and the pad pin
“11”.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
i. Install the brake caliper “12” and the rear
wheel “13”.
Refer to “REAR WHEEL” on page 4-7.
j. Tighten the pad pin “14”.
k. Install the pad pin plug “15” and the protector
“16”.
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3. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-27.
4. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-22.
EASB111095CHECKING THE REAR BRAKE PAD INSU-
LATOR
1. Remove:
• Brake pads
Refer to “REAR BRAKE” on page 4-22.
2. Check:
• Rear brake pad insulator “1”
Damage  Replace.
EASB111096CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle upright on a level surface.
TIP
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the brake
fluid reservoir is horizontal. Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Bolt (protector)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T R..
10 11
a
b
T R..
13
14
12
T R..
15
16

CHASSIS
3-28
2. Check:
• Brake fluid level
The minimum level mark “a” or below 
Add.
EWA
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
EASB111097ADJUSTING THE DRIVE CHAIN SLACKECA13550
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.1. Use a suitable stand to raise the rear wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Shift the transmission into the neutral posi-
tion.
3. Pull the drive chain up above the drive chain
guide installation bolt with a force of about
50 N (5.0 kgf, 36 lbf).
4. Check:
• Drive chain slack “a”
Out of specification  Regulate.
TIP
Measure drive chain slack between the drive
chain guide and the bottom of the chain as
shown.
5. Adjust:
• Drive chain slack
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a. Loosen the wheel axle nut “1”.
b. Loosen both locknuts “2”.
c. Turn the adjusting bolt “3” in direction “a” or
“b” until the specified drive chain slack is ob-
tained. Specified brake fluid
DOT 4
A. Front brake
B. Rear brake
Drive chain slack
50–60 mm (1.97–2.36 in)
Direction “a”
The drive chain slack decreases.
Direction “b”
The drive chain slack increases.
a

CHASSIS
3-29
TIP
• To maintain the proper wheel alignment, ad-
just both sides evenly.
• Push the rear wheel forward to make sure that
there is no clearance between the swingarm
end plates and the ends of the swingarm.
d. Tighten the locknut.
e. Tighten the wheel axle nut.
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EASB111098CHECKING THE FRONT FORK LEGS
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Inner tube
Damage/scratches  Replace.
• Front fork leg (s)
Oil leaks between inner tube and outer tube
 Replace the oil seal.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation  Correct or replace.
Refer to “FRONT FORK” on page 4-38.
EASB111099CHECKING THE FRONT FORK PROTEC-
TOR GUIDE
1. Check:
• Protector guide “1”
Out of specification  Replace.
TIP
The protector guide reaches the limit of its use
when it is worn down to the same height “a” as
of the outer tube circumference.
EASB111100CLEANING THE FRONT FORK OIL SEAL
AND DUST SEAL
1. Remove:
•Protector
• Dust seal “1”
ECA
NOTICE
Be careful not to damage the dust seal and
the inner tube by a driver. Locknut
21 Nm (2.1 m·kgf, 15 ft·lbf)
Wheel axle nut
135 Nm (13.5 m·kgf, 98 ft·lbf)
1
32
a
b
T R..
T R..1
a
1

CHASSIS
3-30
2. Clean:
• Dust seal “a”
• Oil seal “b”
TIP
• Clean the dust seal and oil seal after every
run.
• Apply lithium-soap-based grease on the inner
tube.
EASB111101AIR BLEEDING FROM FRONT FORK
TIP
If the front fork initial movement feels stiff dur-
ing a run, relieve the front fork internal pres-
sure.
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 the air bleed screw “1” and release
the internal pressure from the front fork.
3. Tighten:
• Air bleed screw
EASB111102
ADJUSTING THE FRONT FORK LEGSEWA32D1006
WARNING
• Always adjust the left and right front forks
evenly. If this is not done, the vehicle may
have poor stability.
• Securely support the vehicle so that there
is no danger of it falling over.
Rebound damping
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Rebound damping
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a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
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Air bleed screw
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
LS
a
b
T R..
1
Direction “a”
Rebound damping is increased (sus-
pension is harder).
Direction “b”
Rebound damping is decreased (sus-
pension is softer).
Rebound damping adjusting posi-
tions
Maximum
Fully turned in
Standard
11 clicks out*
Minimum
20 clicks out*
* With the adjuster fully turned in
1
a
b

CHASSIS
3-31
Compression dampingECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Compression damping
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a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
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EASB111103CHECKING THE SWINGARM OPERATION
1. Check:
• Swingarm smooth action
• Swingarm free play
Refer to “SWINGARM” on page 4-62.
EASB111104
CHECKING THE REAR SUSPENSION
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Rear shock absorber assembly
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-55.
3. Check:
• Rear shock absorber assembly smooth ac-
tion
• Rear suspension link smooth action
Sit astride the seat and shake your body up
and down several times to check whether
the rear shock absorber assembly operates
smoothly.
Unsmooth operation  Correct or replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-55.
EASB111105ADJUSTING THE REAR SHOCK ABSORB-
ER ASSEMBLY
Use a suitable stand to raise the rear wheel off
the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
Spring preload
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Remove:
• Rear frame
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-55. Direction “a”
Compression damping is increased
(suspension is harder).
Direction “b”
Compression damping is decreased
(suspension is softer).
Compression damping adjusting
positions
Maximum
Fully turned in
Standard
8 clicks out* (USA) (CAN)
16 clicks out* (EUR) (JPN) (AUS)
(NZL) (ZAF)
Minimum
20 clicks out*
* With the adjuster fully turned in
a b
1

CHASSIS
3-32
2. Adjust:
• Spring preload
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a. Loosen the locknut “1”.
b. Loosen the adjuster “2” until there is some
clearance between the spring and the ad-
juster.
c. Measure the spring free length “a”.
d. Turn the adjuster in the direction of “b” or “c”
to make an adjustment.
TIP
• Be sure to remove all dirt and mud from
around the locknut and adjusting ring before
adjustment.
• The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjusting ring.e. Tighten the locknut.
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3. Install:
• Rear frame
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-55.
Rebound damping
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment. Direction “b”
Spring preload is increased (suspen-
sion is harder).
Direction “c”
Spring preload is decreased (suspen-
sion is softer).
Spring preload adjusting positions
Minimum
Position in which the spring is
turned in 1.5 mm (0.06 in) from
its free length.
Standard
Position in which the spring is
turned in 10 mm (0.39 in) from its
free length.
Maximum
Position in which the spring is
turned in 18 mm (0.71 in) from its
free length.
Locknut
30 Nm (3.0 m·kgf, 22 ft·lbf)
Direction “a”
Rebound damping is increased (sus-
pension is harder).
Direction “b”
Rebound damping is decreased (sus-
pension is softer).
Rebound damping adjusting posi-
tions
Maximum
Fully turned in
Standard
14 clicks out* (USA) (CAN)
12 clicks out* (EUR) (JPN) (AUS)
(NZL) (ZAF)
Minimum
30 clicks out*
* With the adjuster fully turned
c
b
T R..

CHASSIS
3-33
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Compression damping (for fast compres-
sion damping)
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Compression damping (for fast compression
damping)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
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Compression damping (for slow compres-
sion damping)
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Compression damping (for slow compres-
sion damping)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
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Direction “a”
Compression damping is increased
(suspension is harder).
Direction “b”
Compression damping is decreased
(suspension is softer).
Compression damping setting
(for fast compression damping)
Maximum
Fully turned in
Standard
1-1/4 turns out* (USA) (CAN)
1-3/8 turns out* (EUR) (JPN)
(AUS) (NZL) (ZAF)
Minimum
2 turns out*
* With the adjuster fully turned
a
b
1
1
a b
Direction “a”
Compression damping is increased
(suspension is harder).
Direction “b”
Compression damping is decreased
(suspension is softer).
Compression damping setting
(for slow compression damping)
Maximum
Fully turned in
Standard
10 clicks out* (USA) (CAN)
12 clicks out* (EUR) (JPN) (AUS)
(NZL) (ZAF)
Minimum
20 clicks out*
* With the adjuster fully turned in
1ba

CHASSIS
3-34
EASB111106CHECKING THE TIRES
1. Measure:
• Tire pressure
Out of specification  Regulate.
TIP
• Check the tire while it is cold.
• Loose bead stoppers allow the tire to slip off
its position on the rim when the tire pressure
is low.
• If the tire valve stem is found tilted, the tire is
considered to be slipping off its position. Cor-
rect the tire position.
EASB111107CHECKING AND TIGHTENING THE
SPOKES
1. Check:
• Spokes
Bend/damage  Replace.
Loose  Tighten.
TIP
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.2. Tighten:
• Spokes
Use a spoke nipple wrench “1” for tighten-
ing.
TIP
• Do not give a half turn (180 °) or more for one
tightening.
• Make sure that tightening after a break-in is
done until the initial looseness in nipples dis-
appears.
• Make sure that tightening is done in stages,
not at a time.
EASB111108CHECKING THE WHEELS
1. Check:
• Wheel(s)
Damage/out-of-round  Replace.
EWA
WARNING
Never attempt to make any repairs to the
wheel.
TIP
After replacing a tire or a wheel, always bal-
ance the wheel.
EASB111109CHECKING THE WHEEL BEARINGS
1. Check:
• Wheel bearings
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4 and “CHECKING THE REAR
WHEEL” on page 4-8. Tire air pressure (measured on cold
tires)
Front
100 kPa (1.00 kgf/cm
2, 15 psi)
Rear
100 kPa (1.00 kgf/cm
2, 15 psi)
Spoke nipple wrench (6–7)
90890-01521
YM-01521
Spokes
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
1
T R..

CHASSIS
3-35
EASB111110CHECKING AND ADJUSTING THE STEER-
ING HEAD
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. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  Adjust the steering
head.
3. Remove:
• Handlebar
Refer to “HANDLEBAR” on page 4-32.
• Upper bracket
Refer to “STEERING HEAD” on page 4-51.
4. Adjust:
• Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the washer “1”.
b. After loosening the ring nut “2” with a steer-
ing nut wrench “3”, tighten it to the specified
torque.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly.c. Turn the front fork to the right and left a few
times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly,
remove the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 4-51.
d. Loosen the ring nut fully turn and then tight-
en it to specification with a steering nut
wrench.
EWA
WARNING
Do not overtighten the lower ring nut.
e. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-51.
f. Install the washer “1”.
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1
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
Ring nut (initial tightening torque)
38 Nm (3.8 m·kgf, 27 ft·lbf)
Ring nut (final tightening torque)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
3
2
T R..
T R..
1

CHASSIS
3-36
5. Install:
• Upper bracket
Refer to “STEERING HEAD” on page 4-51.
• Handlebar
Refer to “HANDLEBAR” on page 4-32.
EASB111111LUBRICATING THE LEVERS
1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
• Brake lever
•Clutch lever
EASB111112LUBRICATING THE PEDAL
1. Lubricate the pivoting point and metal-to-
metal moving parts of the pedal.Recommended lubricant
Silicone grease
Recommended lubricant
Lithium-soap-based grease
Recommended lubricant
Lithium-soap-based grease