steering YAMAHA WR 450F 2003 User Guide

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INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
Tighten the ring nut 3 using ring nut
wrench 4.
NOTE:
Set the torque wrench to the ring nut wrench
so that they form a right angle.
Ring nut wrench:
YU-33975/90890-01403
T R..
Ring nut (initial tightening):
38 Nm (3.8 m • kg, 27 ft • lb)
Loosen the ring nut one turn.
Retighten the ring nut using the ring nut
wrench.
WARNING
Avoid over-tightening.
T R..
Ring nut (final tightening):
7 Nm (0.7 m • kg, 5.1 ft • lb)
Check the steering shaft by turning it lock
to lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
Install the plain washer 5, handle crown
6, plain washer 7, steering shaft nut 8,
steering shaft cap 9, handlebar 0, han-
dlebar holder A and headlight B.
NOTE:
The handlebar holder should be installed
with the punched mark a forward.
Insert the end of the fuel breather hose C
into the hole in the steering shaft cap.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.
T R..
Steering shaft nut:
145 Nm (14.5 m • kg, 105 ft • lb)
Handlebar holder:
28 Nm (2.8 m • kg, 20 ft • lb)
Pinch bolt (handle crown):
23 Nm (2.3 m • kg, 17 ft • lb)
Headlight (left and right):
10 Nm (1.0 m • kg, 7.2 ft • lb)
Headlight (lower):
7 Nm (0.7 m • kg, 5.1 ft • lb)

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CHASHANDLEBAR
11. Install:
Clutch cable 1
Hot starter cable 2
NOTE:
Apply the lithium soap base grease on the
clutch cable end and hot starter cable end.
12. Adjust:
Clutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
Hot starter lever free play
Refer to “HOT STARTER LEVER
ADJUSTMENT” section in the CHAP-
TER 3.
13. Fasten the hot starter cable 1 and clutch
cable 2 with a clamp 3.
1
2
3
14. Insert the end of the fuel breather hose
1 into the hole in the steering shaft cap
2.
1
2

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CHAS
EC560000
STEERING
Extent of removal:1 Under bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is no
danger of it falling over.
Refer to “HANDLEBAR” section. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Headlight
Handlebar
Hose guide
Front fender
1 Coupler bracket 1
2 Trip meter 1
3 Main switch 1 Disconnect the main switch lead.
4 Steering shaft cap 1
5 Steering shaft nut 1
6 Front fork 2 Refer to “FRONT FORK” section.
7 Handle crown 1
8 Ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
9 Under bracket 1
10 Ball race cover 1
2
1
STEERING

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CHASSTEERING
Extent of removal Order Part name Q’ty Remarks
11 Bearing (upper) 1
12 Bearing (lower) 1
Refer to “REMOVAL POINTS”.
13Ball race
2
2

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CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
Ring nut 1
Use the ring nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Ring nut wrench:
YU-33975/90890-01403
EC563300
Bearing (lower)
1. Remove:
Bearing (lower) 1
Use the floor chisel 2.
ACHTUNG:CAUTION:
Take care not to damage the steering shaft
thread.
EC563400
Ball race
1. Remove:
Ball race 1
Remove the ball race using long rod 2
and the hammer.
EC564000
INSPECTION
EC564200
Steering shaft
1. Inspect:
Steering shaft 1
Bend/damage → Replace.
STEERING

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CHASSTEERING
EC564101
Bearing and ball race
1. Wash the bearings and ball races with a
solvent.
2. Inspect:
Bearing 1
Ball race
Pitting/damage → Replace bearings
and ball races as a set.
Install the bearing in the ball races.
Spin the bearings by hand. If the bear-
ings hang up or are not smooth in their
operation in the ball races, replace
bearings and ball races as a set.
EC565000
ASSEMBLY AND INSTALLATION
Under bracket
1. Install:
Bearing (lower) 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
Ball race
Bearing (upper) 1
Ball race cover 2
NOTE:
Apply the lithium soap base grease on the
bearing and ball race cover lip.
3. Install:
Under bracket 1
NOTE:
Apply the lithium soap base grease on the
bearing and the portion a of the steering
shaft.

5 - 50
CHAS
4. Install:
Plain washer 1
Ring nut 2
Tighten the ring nut using the ring nut
wrench 3.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
5. Check the steering shaft by turning it lock
to lock. If there is any binding, remove
the steering shaft assembly and inspect
the steering bearings.
6. Install:
Plain washer 1
7. Install:
Front fork 1
Handle crown 2
Main switch 3
Coupler bracket 4
Hose guide bracket 5
NOTE:
Install the coupler bracket on the outside of
the hose guide bracket.
Temporarily tighten the pinch bolts (under
bracket).
Do not tighten the pinch bolts (handle crown)
yet.
8. Install:
Plain washer 1
Steering shaft nut 2
T R..145 Nm (14.5 m · kg, 105 ft · lb)
STEERING

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CHASSTEERING
9. Install:
Steering shaft cap 1
10. After tightening the nut, check the steer-
ing for smooth movement. If not, adjust
the steering by loosening the ring nut little
by little.
11. Adjust:
Front fork top end a
Front fork top end (standard) a:
Zero mm (Zero in)
12. Tighten:
Pinch bolt (handle crown) 1
Pinch bolt (under bracket) 2
ACHTUNG:CAUTION:
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
13. Install:
Trip meter 1
Bolt (trip meter) 2
NOTE:
Install the trip meter over the coupler bracket
3.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)