ABS YAMAHA WR 450F 2006 Manual Online

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CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:
1 Rear shock absorber removal
2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
REAR SHOCK ABSORBER
REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Seat, fitting band and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
Air filter cover Refer to “AIR FILTER CLEANING” sec-
tion in the CHAPTER 3.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Coolant reservoir tank breather
hoseDisconnect at the coolant reservoir tank
side.
Coolant reservoir hose Disconnect at the coolant reservoir tank
side.
Air induction hose (air cut-off
valve-air filter case)Disconnect at the air filter case side.

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CHAS
FEDERBEIN
Arbeitsumfang:
1 Federbein demontieren
2 Federbein zerlegen
ArbeitsumfangReihen-
folgeBauteil Anz. Bemerkungen
FEDERBEIN DEMONTIEREN
WARNUNGDas Fahrzeug sicher abstützen, damit es nichtumfallen kann. Vorbereitungsarbeiten Das Motorrad am Motor aufbokken und in
gerader Stellung halten.
Sitzbank, Haltegummi und Seitenabdek-
kungenSiehe unter “SITZBANK, KRAFTSTOFFTANK UND
SEITENABDECKUNGEN” in KAPITEL 4.
Luftfilter-Gehäusedeckel Siehe unter “LUFTFILTER REINIGEN” in KAPITEL
3.
Schalldämpfer Siehe unter “AUSPUFFKRÜMMER UND SCHALL-
DÄMPFER” in KAPITEL 4.
Die Kühlflüssigkeit ablassen. Siehe unter “KÜHLFLÜSSIGKEIT WECHSELN” in
KAPITEL 3.
Ausgleichsbehälter-Entlüftungsschlauch Ausgleichsbehälterseitig lösen.
Ausgleichsbehälter-Schlauch Ausgleichsbehälterseitig lösen.
Abschaltventil/Luftfiltergehäuse-Sekundär-
luftsystem-SchlauchLuftfiltergehäuseseitig lösen.
AMORTISSEUR ARRIERE
Organisation de la dépose:1 Dépose de l’amortisseur arrière2 Démontage de l’amortisseur arrière
Organisation de la dépose Ordre Nom de la pièce QtéRemarques
DEPOSE DE L’AMORTISSEUR ARRIERE
AVERTISSEMENTBien caler la moto afin qu’elle ne risque pas de bascu-ler. Préparation à la dépose Caler la moto en plaçant un support adéquat
sous le moteur.
Selle, bande de fixation et caches latéraux Se reporter à la section “SELLE, RESERVOIR DE CAR-
BURANT ET CACHES LATERAUX” au CHAPITRE 4.
Couvercle de filtre à air Se reporter à la section “NETTOYAGE DU FILTRE A
AIR” au CHAPITRE 3.
Silencieux Se reporter à la section “TUBE D’ECHAPPEMENT ET
SILENCIEUX” au CHAPITRE 4.
Vidanger le liquide de refroidissement. Se reporter à la section “CHANGEMENT DU LIQUIDE
DE REFROIDISSEMENT” au CHAPITRE 3.
Durit de mise à l’air du vase d’expansion Débrancher du côté vase d’expansion de liquide de refroi-
dissement.
Durit du vase d’expansion Débrancher du côté vase d’expansion de liquide de refroi-
dissement.
Durit d’induction d’air (clapet de coupure d’air
- boîtier de filtre à air)La débrancher sur le côté du boîtier du filtre à air.
AMORTIGUADOR TRASERO
Extensión del desmontaje:1 Desmontaje del amortiguador trasero2 Desarmado del amortiguador trasero
Extensión del desmontaje Orden Nombre de la pieza Ctd. Observaciones
DESMONTAJE DEL AMORTIGUADOR
TRASERO
ADVERTENCIA
Sujete firmemente la máquina de forma que no existariesgo de que se caiga. Preparación para el desmontaje Sujete la máquina colocando un soporte ade-
cuado debajo del motor.
Sillín, banda de sujeción y cubiertas laterales Consulte el apartado “SILLÍN, DEPÓSITO DE COM-
BUSTIBLE Y CUBIERTAS LATERALES” del CAPÍ-
TULO 4.
Tapa del filtro de aire Consulte el apartado “LIMPIEZA DEL FILTRO DE
AIRE” del CAPÍTULO 3.
Silenciador Consulte el apartado “TUBO DE ESCAPE Y SILENCIA-
DOR”del CAPÍTULO 4.
Vacíe el refrigerante. Consulte el apartado “CAMBIO DEL REFRIGERANTE”
del CAPÍTULO 3.
Tubo respiradero del depósito de refrigerante Desconéctelo en el lado del depósito de refrigerante.
Tubo del depósito de refrigerante Desconéctelo en el lado del depósito de refrigerante.
Tubo de inducción de aire (válvula de corte de
aire-carcasa del filtro de aire)Desconectar en el lado de la carcasa del filtro de aire.
AMORTISSEUR ARRIERE
FEDERBEIN
AMORTIGUADOR TRASERO

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CHASREAR SHOCK ABSORBER
Extent of removal Order Part name Q’ty Remarks
Cylinder head breather hose Disconnect at the air filter case side.
Battery Refer to “BATTERY INSPECTION AND
CHARGING” section in the CHAPTER 3.
Disconnect the starter relay cou-
pler.
Starter motor lead Disconnect at the starter relay side.
1 Locking tie 3
2 Taillight coupler 1
3 Starting circuit cut-off relay cou-
pler1
4 Plastic band 2
5 Clamp (air filter joint) 1 Only loosening.
6Rear frame 1
7 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
8 Bolt (rear shock absorber-frame) 1
21

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CHASREAR SHOCK ABSORBER
Extent of removal Order Part name Q’ty Remarks
9 Rear shock absorber 1
10 Locknut 1 Only loosening.
11 Adjuster 1 Only loosening.
12 Spring guide (lower) 1
13 Spring guide (upper) 1
14 Spring (rear shock absorber) 1
15 Bearing 2 Refer to “REMOVAL POINTS”.
2
1

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CHAS
EC586000
HANDLING NOTE
WARNING
This shock absorber is provided with a
separate type tank filled with high-pressure
nitrogen gas. To prevent the danger of
explosion, read and understand the follow-
ing information before handling the shock
absorber.
The manufacturer can not be held respon-
sible for property damage or personal
injury that may result from improper han-
dling.
1. Never tamper or attempt to disassemble
the cylinder or the tank.
2. Never throw the shock absorber into an
open flame or other high heat. The
shock absorber may explode as a result
of nitrogen gas expansion and/or dam-
age to the hose.
3. Be careful not to damage any part of the
gas tank. A damaged gas tank will impair
the damping performance or cause a
malfunction.
4. Take care not to scratch the contact sur-
face of the piston rod with the cylinder;
or oil could leak out.
5. Never attempt to remove the plug at the
bottom of the nitrogen gas tank. It is
very dangerous to remove the plug.
6. When scrapping the shock absorber, fol-
low the instructions on disposal.
EC587000
NOTES ON DISPOSAL (YAMAHA DEALERS
ONLY)
Before disposing the shock absorber, be sure
to extract the nitrogen gas from valve 1. Wear
eye protection to prevent eye damage from
escaping gas and/or metal chips.
WARNING
To dispose of a damaged or worn-out
shock absorber, take the unit to your
Yamaha dealer for this disposal procedure.
REAR SHOCK ABSORBER

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CHAS
EC583000
REMOVAL POINTS
EC583320
Bearing
1. Remove:
•Stopper ring (upper bearing) 1
NOTE:
Press in the bearing while pressing its outer
race and remove the stopper ring.
2. Remove:
•Upper bearing 1
NOTE:
Remove the bearing by pressing its outer race.
3. Remove:
•Lower bearing 1
NOTE:
Remove the bearing by pressing its outer race.
EC584000
INSPECTION
Rear shock absorber
1. Inspect:
•Damper rod 1
Bends/damage → Replace absorber
assembly.
•Shock absorber 2
Oil leaks → Replace absorber assembly.
Gas leaks → Replace absorber assem-
bly.
•Spring 3
Damage → Replace spring.
Fatigue → Replace spring.
Move spring up and down.
•Spring guide 4
Wear/damage → Replace spring guide.
•Bearing 5
Free play exists/unsmooth revolution/rust
→ Replace.
REAR SHOCK ABSORBER

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CHASREAR SHOCK ABSORBER
EC585000
ASSEMBLY AND INSTALLATION
EC585300
Bearing
1. Install:
•Upper bearing 1
NOTE:
Install the bearing parallel until the stopper ring
groove appears by pressing its outer race.
CAUTION:
Do not apply the grease on the bearing
outer race because it will wear the rear
shock absorber surface on which the bear-
ing is press fitted.
2. Install:
•Stopper ring (upper bearing) 1
NOTE:
After installing the stopper ring, push back the
bearing until it contacts the stopper ring.
New
3. Install:
•Lower bearing 1
NOTE:
Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of the bearing
a:
4 mm (0.16 in)
EC585111
Spring (rear shock absorber)
1. Install:
•Spring 1
•Spring guide (upper) 2
•Spring guide (lower) 3

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CHASREAR SHOCK ABSORBER
2. Tighten:
•Adjuster 1
3. Adjust:
•Spring length (installed)
Refer to “REAR SHOCK ABSORBER
SPRING PRELOAD ADJUSTMENT” sec-
tion in the CHAPTER 3.
4. Tighten:
•Locknut 1
Rear shock absorber
1. Install:
•Dust seal 1
•O-ring 2
•Collar 3
NOTE:
•Apply the molybdenum disulfide grease on
the dust seal lips and collars.
•Apply the lithium soap base grease on the O-
rings.
New

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CHASREAR SHOCK ABSORBER
2. Install:
•Bush 1
•Collar 2
•Dust seal 3
NOTE:
•Apply the molybdenum disulfide grease on
the bearing and dust seal lips.
•Install the dust seals with their lips facing out-
ward.
3. Install:
•Rear shock absorber
4. Install:
•Bolt (rear shock absorber-frame) 1
•Nut (rear shock absorber-frame) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
5. Install:
•Bolt (rear shock absorber-relay arm) 1
•Nut (rear shock absorber-relay arm) 2
NOTE:
Apply the molybdenum disulfide grease on the
bolt.
T R..56 Nm (5.6 m · kg, 40 ft · lb)
T R..53 Nm (5.3 m · kg, 38 ft · lb)
6. Install:
•Rear frame 1
•Bolt [rear frame (upper)] 2
•Bolt [rear frame (lower)] 3
T R..32 Nm (3.2 m · kg, 23 ft · lb)
T R..29 Nm (2.9 m · kg, 21 ft · lb)
7. Tighten:
•Screw (air filter joint) 1
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)

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CHAS
8. Install:
•Plastic band 1
•Starting circuit cut-off relay coupler 2
•Taillight coupler 3
•Locking tie 4
REAR SHOCK ABSORBER