brake YAMAHA WR 450F 2007 Owner's Guide

4 - 94
ENGENGINE REMOVAL
Drive sprocket
1. Install:
Drive sprocket 1
Drive chain 2
NOTE:
Install the drive sprocket together with the
drive chain.
2. Install:
Lock washer 1
Nut (drive sprocket) 2
NOTE:
Tighten the nut while applying the rear brake.
New
T R..75 Nm (7.5 m · kg, 54 ft · lb)
3. Bend the lock washer tab to lock the nut.
4. Install:
Chain guide
Chain cover 1
Screw (chain cover) 2
21T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
5. Install:
Spring 1
Pin 2
O-ring 3
Neutral switch 4
Screw (neutral switch) 5
NOTE:
Apply the lithium soap base grease on the O-
ring.
New
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)

5 - 1
CHAS
EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1 Front wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
FRONT WHEEL 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.
1 Bolt (axle holder) 4 Only loosening.
2 Nut (front wheel axle) 1
3 Front wheel axle 1
4 Front wheel 1
5 Speed sensor 1
6 Collar 1
7 Oil seal 1
8 Bearing 2 Refer to “REMOVAL POINTS”.
9 Brake disc 1
2
13
3

5 - 2
CHAS
EC598100
REAR WHEEL
Extent of removal:
1 Rear wheel removal
2 Wheel bearing removal
3 Brake disc removal
Extent of removal Order Part name Q’ty Remarks
REAR WHEEL 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.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Driven sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10 Brake disc 1
3
3
1
2
FRONT WHEEL AND REAR WHEEL

5 - 4
CHASFRONT WHEEL AND REAR WHEEL
EC514200
Wheel axle
1. Measure:
Wheel axle bends
Out of specification → Replace.
Use the dial gauge 1.
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent axle.
Wheel axle bending limit:
0.5 mm (0.020 in)
EC594200
Brake disc
1. Measure:
Brake disc deflection (only rear brake
disc)
Use the dial gauge 1.
Out of specification → Inspect wheel
runout.
If wheel runout is in good condition,
replace the brake disc.
2. Measure:
Brake disc thickness a
Out of limit → Replace.
Disc deflection limit:
Standard
Rear—0.15 mm
(0.006 in)
Disc wear limit:
Standard
Front3.0 mm (0.12 in) 2.5 mm (0.10 in)
Rear4.0 mm (0.16 in) 3.5 mm (0.14 in)

5 - 5
CHASFRONT WHEEL AND REAR WHEEL
EC595000
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:
Bearing (left) 1
Spacer 2
Bearing (right) 3
Oil seal 4
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Left side of bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
Brake disc 1
Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
New
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
4. Install:
Speed sensor 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip of the speed sensor.
Make sure the two projections a in the
wheel hub are meshed with the two slots b
in the speed sensor.
b a1
B

5 - 6
CHASFRONT WHEEL AND REAR WHEEL
5. Install:
Wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
Make sure that the projections a in the
speed sensor fits over the stopper b on the
front fork inner tube.
6. Install:
Wheel axle 1
NOTE:
Apply the lithium soap base grease on the
wheel axle.
7. Install:
Nut (wheel axle) 1
T R..90 Nm (9.0 m · kg, 65 ft · lb)

5 - 7
CHASFRONT WHEEL AND REAR WHEEL
8. Tighten:
Bolt (axle holder) 1
NOTE:
Before tightening the bolt, fit the wheel axle to
the axle holder by stroking the front fork sev-
eral times with the front brake applied.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
Rear wheel
1. Install:
Bearing (right) 1
Circlip 2
Spacer 3
Bearing (left) 4
Oil seal 5
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Install the bearing with seal facing outward.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Right side of bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
New

5 - 8
CHAS
2. Install:
Brake disc 1
Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..14 Nm (1.4 m · kg, 10 ft · lb)
3. Install:
Driven sprocket 1
Bolt (driven sprocket) 2
Plain washer (driven sprocket) 3
Nut (driven sprocket) 4
NOTE:
Tighten the nuts in stage, using a crisscross
pattern.
T R..50 Nm (5.0 m · kg, 36 ft · lb)
4. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5. Install:
Wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
6. Install:
Drive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
FRONT WHEEL AND REAR WHEEL

5 - 10
CHASFRONT BRAKE AND REAR BRAKE
EC5A0000
FRONT BRAKE AND REAR BRAKE
EC5A8000
FRONT BRAKE
Extent of removal:
1 Brake hose removal
2 Caliper removal
3 Master cylinder removal
Extent of removal Order Part name Q’ty Remarks
FRONT BRAKE 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.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake hose holder (protector) 2
2 Brake hose holder (caliper) 1
3 Union bolt 2
4 Brake hose 1
5 Pad pin plug 1 Remove when loosening the pad pin.
6 Pad pin 1 Loosen when disassembling the caliper.
7 Caliper 1
8Brake lever 1
9 Master cylinder bracket 1
10 Master cylinder
1
1
2
3
3
2

5 - 11
CHAS
EC5A8100
REAR BRAKE
Extent of removal:
1 Master cylinder removal
2 Brake hose removal
3 Caliper removal
Extent of removal Order Part name Q’ty Remarks
REAR BRAKE 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.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake pedal 1
2 Master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8 Caliper 1
1
123
3
FRONT BRAKE AND REAR BRAKE