YAMAHA WR 450F 2016 Owners Manual

REAR BRAKE
5-29
EAS2GC1187INSTALLING THE BRAKE CALIPER PISTON
1. Clean:• Brake caliper
• Brake caliper piston seal
• Brake caliper piston dust seal
• Brake caliper pistonUse brake fluid for cleaning.
2. Install: • Brake caliper piston seals “1”
• Brake caliper piston dust seal “2”
EWA
WARNING
Always use new brake caliper piston seal
and brake caliper piston dust seal.
TIP
• Apply the silicone grease on the brake caliper
piston seal and brake caliper piston dust seal.
• Fit the brake caliper piston seals and brake caliper piston dust seals onto the slot on
brake caliper correctly.
3. Install: • Brake caliper piston “1”
TIP
Apply the brake fluid on the piston outer sur-
face.
ECA
NOTICE
• Install the piston with its side “a” facing the brake caliper.
• Never force to insert.
EAS2GC1188INSTALLING THE REAR BRAKE CALIPER
1. Install:
• Rear brake caliper
• Rear brake caliper bracket
2. Install: • Rear wheelRefer to “REAR WHEEL” on page 5-9.
• Copper washers
• Brake hose
• Union bolt
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
NOTICE
Make sure that a bend in its pipe portion “a”
is directed as shown and the brake hose
touches the projection “b” on the brake cal-
iper.
3. Install: • Brake pad springs
• Brake pads
• Brake pad pin
• Brake pad pin plug
Refer to “CHECKING THE REAR BRAKE
PADS” on page 3-29.
4. Pour brake fluid to the brake fluid reservoir up to the specified level.
EWA
New
New
2
1
1
a1
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
Brake pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake pad pin plug 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Specified brake fluid DOT 4
New
T R..
b
b a
T R..

REAR BRAKE
5-30
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.
5. Bleed:• Brake system
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
6. Check:
• Brake fluid levelThe minimum level mark “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30.
7. Check: • Brake pedal operationA softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
EAS2GC1189REMOVING THE REAR BRAKE MASTER
CYLINDER
TIP
Before removing the rear brake master cylin-
der, drain the brake fluid from the entire brake
system. 1. Remove:
• Union bolt
• Copper washers
• Brake hose
TIP
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EAS2GC1190CHECKING THE REAR BRAKE MASTER
CYLINDER
1. Check:• Brake master cylinder “1”
Damage/scratches/wear  Replace.
• Brake fluid delivery passages “2” (brake master cylinder body)
Obstruction  Blow out with compressed
air.
2. Check: • Brake master cylinder kit
Damage/wear  Replace.
3. Check: • Master cylinder reservoir capCrack/damage  Replace.
• Brake master cylinder reservoir diaphragm holder
• Brake master cylinder reservoir diaphragm
Crack/damage  Replace.
4. Check: • Brake hoses
Cracks/damage/wear  Replace.
EAS2GC1191ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
EWA
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.
a
1 2

REAR BRAKE
5-31
1. Wash the brake master cylinder and the brake master cylinder kit with brake fluid.
2. Install: • Primary cylinder cup “1”
• Secondary cylinder cup “2”
Install to the brake master cylinder piston
“3”.
EWA
WARNING
Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.
3. Install:• Spring “1”
Install to the brake master cylinder piston
“2”.
TIP
Install the spring with a smaller inside diameter
to the brake master cylinder piston. 4. Install:
• Master cylinder kit “1”
• Push rod “2”
• Circlip “3”
• Dust boot “4”
TIP
• Before installation, apply brake fluid to the brake master cylinder kit.
• Before installation, apply silicone grease to the push rod end.
• Use circlip pliers to install the circlip.
EAS2GC1192INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:• Copper washers
• Brake hose
• Union bolt
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
NOTICE
Make sure that the pipe portion of the brake
hose touches the projection “a” on the
brake caliper.
Specified brake fluid
DOT 4
2
3
1
23
1
Brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf)
12
New
New
1 3
4
2NewNew
New
T R..

REAR BRAKE
5-32
2. Pour brake fluid to the brake fluid reservoir up to the specified level.
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.
3. Bleed:
• Brake systemRefer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
4. Check: • Brake fluid level
The minimum level mark “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30. 5. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
Specified brake fluid
DOT 4
a
a

HANDLEBAR
5-33
EAS2GC1193
HANDLEBAR
Removing the handlebar
OrderPart name Q’tyRemarks
1 Clutch cable 1 Disconnect.
2 Clutch switch 1
3 Clutch lever holder 1
4 Engine stop switch 1
5 Brake master cylinder 1
6 Throttle cable cap 1
7 Throttle cable (pull) 1 Disconnect.
8 Throttle cable (return) 1 Disconnect.
9 Right grip 1
10 Tube guide 1
11 Start switch 1
12 Left grip 1
13 Handlebar upper holder 2
14 Handlebar 1

HANDLEBAR
5-34
15 Handlebar lower holder2
16 Damper 4
For installation, reverse the removal proce-
dure.
Removing the handlebar
Order Part name Q’tyRemarks

HANDLEBAR
5-35
EAS2GC1194REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:•Clutch switch “1”
TIP
Press the projection, and remove it from the
clutch lever assembly.
3. Remove:• Handlebar grip “1”
TIP
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
4. Remove:
• Throttle cable housings “1”
• Throttle grip “2”
TIP
While removing the throttle cable housing, pull
back the rubber cover “3”.
EAS2GC1195CHECKING THE HANDLEBAR
1. Check:• Handlebar
Bends/cracks/damage  Replace.
EWA
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS2GC1196INSTALLING THE HANDLEBAR
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. Install:
• Damper “1”
• Lower handlebar holders“2” (temporarily)
• Handlebar “3”
• Upper handlebar holders “4”
TIP
• Install the lower handl ebar holders with them
side having the greater distance “a” from the
mounting bolt center facing forward.
• Installing the lower handlebar holders in the
reverse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• The upper handlebar holders should be in- stalled with the punch marks “b” facing for-
ward.
• When installing the handlebar, make sure that right and left marks “c” are in place identically
on both sides.
• Install the handlebar so that the projection “d” of the upper handlebar holders is positioned
at the mark on the handlebar as shown.
ECA
Upper handlebar holder bolt28 Nm (2.8 m·kgf, 20 ft·lbf)
T R..

HANDLEBAR
5-36
NOTICE
• First, tighten the bolts on the front side of the upper handlebar holder, and then on
the rear side.
• Turn the handlebar all the way to the left and right. If there is any contact with the
fuel tank, adjust the handlebar position.
3. Tighten:• Lower handlebar holder nut
4. Install: • Handlebar grip “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly coat the handlebar left end with a rubber adhesive.
b. Install the handlebar grip on the handlebar by pressing the grip from the left side.
c. Wipe off any excess adhesive with a clean cloth.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Install the handlebar grip to the handlebar so
that the line “a” between the two arrow marks
faces straight upward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
1
1
a
3
4
Lower handlebar holder nut40 Nm (4.0 m·kgf, 29 ft·lbf)
T R..

HANDLEBAR
5-37
5. Install:• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
•Clamp “4”
TIP
• The engine stop switch, the clutch lever, and the clutch lever holder should be installed ac-
cording to the dimensions shown.
• Pass the engine stop switch lead through the
middle of the clutch lever holder.
6. Install: • Right grip “1”
• Collar “2”Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the grip match mark “b” and tube guide slot “c”
form the angle as shown. 7. Install:
• Rubber cover “1”
• Throttle grip “2”
TIP
Apply the lithium-soap-based grease on the
throttle grip sliding surface.
8. Install:• Throttle cables “1”
TIP
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle-
bar.
9. Install:
• Throttle cable housings “1”
• Screw (throttle cable housings) “2”
EWA
Engine stop switch screw0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
Screw (throttle cable housings)3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
64
1 b
c
3
64
T R..

HANDLEBAR
5-38
WARNING
After tightening the throttle cable housing
screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the
screws for adjustment.
10.Install:• Rubber cover “1”
• Cover (throttle cable housings) “2”
11.Install: • Start switch “1”
• Front brake master cylinder assembly “2”
• Front brake master cylinder holder “3”
• Bolt (brake master cylinder holder) “4”
•Clamp “5”
TIP
• Install the brake master cylinder holder with the “UP” mark facing up.
• Install in order for the top of the front brake master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.
12.Install: • Clutch cable “1”
TIP
Before installation, apply the lithium-soap-
based grease to the clutch cable end.
13.Adjust:• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LE-
VER FREE PLAY” on page 3-12.
Front brake master cylinder hold-
er bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T R..
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
2
5
1
4
3
4
1LS