torque YAMAHA WR 450F 2016 Owner's Manual

CHASSIS
4-6
EAS2GC1148SUSPENSION SETTING (FRONT FORK)
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absor ber sunken length to the standard figure 90–100 mm
(3.5–3.9 in).
Symptom Section
CheckAdjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff over entire
range Compression
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil amount Decrease oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with soft spring.
Unsmooth
movement over
entire range Outer tube
Inner tube
Check for any bends, dents,
other noticeable scars, etc. If
any, replace affected parts.
Slide metal Replace with a new one for ex- tended use.
Piston metal Replace with a new one for ex- tended use.
Lower bracket
tightening
torque Retighten to specified torque.
Poor initial
movement Rebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil seals Apply grease in oil seal wall.
Soft over entire
range, bottom-
ing out Compression
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Oil amount Increase oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with stiff spring.
Stiff toward
stroke end Oil amountDecrease oil amount by about
5 cm
3 (0.2 US oz, 0.2 Imp.oz).
Soft toward
stroke end, bot-
toming out Oil amountIncrease oil amount by about 5
cm
3 (0.2 US oz, 0.2 Imp.oz).
Stiff initial
movement Compression
damping forceTurn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.

FRONT FORK
5-51
2. Tighten:• Damper assembly “1”
TIP
Use the cap bolt ring wrench “2” to tighten the
damper assembly.
3. Adjust:
• Front fork top end “a” 4. Tighten:
• Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:• Speed sensor lead “1”
• Plate 1 “2”(to the right front fork protector)
TIP
Install the speed sensor lead so that its paint “a”
directs as shown and align the bottom “b” of the
plate 1 with the same paint.
Damper assembly
30 Nm (3.0 m·kgf, 22 ft·lbf)
Cap bolt ring wrench 90890-01501
Cap bolt ring wrench YM-01501
Front fork top end (standard) “a” 5 mm (0.20 in)
T R..
2
1
a
Upper bracket pinch bolts21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf)
Plate 1 bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
T R..
2 1
T R..
1
2
a
b

STEERING HEAD
5-57
TIP
Apply the lithium-soap-based grease to the
contact surface of the steering stem nut when
installing.
9. After tightening the nut, check the steering for smooth movement. If not, adjust the
steering by loosening the steering ring nut
little by little.
10.Adjust:
• Front fork top end “a”
11.Tighten: • Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction. 12.Install:
• Speed sensor lead holder “1”
• Speed sensor lead clamp “2”
TIP
• Insert the end of the speed sensor lead holder
in the hole in the lower bracket “a”.
• Install so that the marking “b” on the speed sensor lead aligns with the speed sensor lead
holder edge.
• Install the speed sens or lead clamp while in-
serting it in the hole “c” in the speed sensor
lead holder.
Front fork top end (standard) “a”
5 mm (0.20 in)
Upper bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf)
a
T R..
T R..
Speed sensor lead holder bolt13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Speed sensor lead clamp bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2 1
T R..

SWINGARM
5-66
EAS2GC1217REMOVING THE SWINGARM
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Measure:• Swingarm side play
• Swingarm vertical movement
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a. Measure the tightening torque of the pivot shaft nut.
b. Measure the swingarm side play “a” by mov- ing the swingarm from side to side.
c. If the swingarm side play is out of specifica- tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b” by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
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EAS2GC1218REMOVING THE BEARING
1. Remove:• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1219CHECKING THE SWINGARM
1. Check:• Swingarm
Bends/cracks/damage  Replace.
2. Check: • Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check: • Oil seals
Damage  Replace.
• Bearing
• Spacers Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set.
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial) 1.0 mm (0.04 in)
T R..

CAMSHAFT
6-16
EAS2GC1242CHECKING THE DECOMPRESSION SYS-
TEM
1. Check:• Decompression system
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a. Check that the decompressor cam “1”
moves smoothly.
b. Check that the decompressor lever pin “2” projects from the camshaft.
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EAS2GC1243INSTALLING THE CAMSHAFTS
1. Install:• Exhaust camshaft “1”
• Intake camshaft “2”
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a. Turn the crankshaft counterclockwise with a
wrench.
TIP
• Apply molybdenum disulfide oil to the cam-shafts.
• Apply the engine oil on the decompression
system.
b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the
crankcase cover. c. Fit the timing chain “3” onto both camshaft
sprockets and install the camshafts on the
cylinder head.
TIP
Make sure that the alignment mark “c” on the
exhaust camshaft sprocket and the alignment
mark “d” on the intake camshaft sprocket are
aligned with the edge of the cylinder head.
ECA
NOTICE
Do not turn the crankshaft during the cam-
shaft installation. Damage or improper
valve timing will result.
d. Install the clips, the camshaft caps and the bolts (camshaft cap).
TIP
• Before installing the clips, cover the cylinder head with a clean cloth to prevent the clips
from coming off into the cylinder head cavity.
• Apply the engine oil to the threads and con- tact surfaces.
• Tighten the bolts to the specified torque in two or three steps in the proper tightening se-
quence as shown.
ECA
NOTICE
The bolts (camshaft cap) must be tightened
evenly, or damage to the cylinder head,
camshaft caps, and camshaft will result.
1
2
Bolt (camshaft cap)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
ab
c
3
d
T R..

CYLINDER HEAD
6-21
EAS2GC1248INSTALLING THE CYLINDER HEAD
1. Install:• Timing chain guide (intake side) “1”
• Dowel pins “2”
• Cylinder head gasket
• Dowel head “4”
TIP
While pulling up the timing chain, install the tim-
ing chain guide (intake side) and the cylinder
head.
2. Install:• Washer “1”
• Cylinder head bolt “2”
• Engine ground sub-lead “3”
• Cylinder head bolt “4”
TIP
Tighten the bolts using the following procedure.
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a. Wash the threads and contact surfaces of the bolts, the contact surfaces of the wash-
ers, the contact surface of the cylinder head,
and the threads of the crankcase.
b. Apply molybdenum disulfide grease to the threads and contact surfaces of the bolts
and to both contact surfaces of the washers
“1”.
c. Install the washers and the bolts.
d. Tighten the bolts to the specified torque in
two or three steps in the proper tightening
sequence as shown. e. Remove the bolts.
f. Again apply molybdenum disulfide grease to
the threads and contact surfaces of the bolts
and to both contact surfaces of the washers.
g. Retighten the bolts.
TIP
Tighten the bolts to the specified torque in two
or three steps in the proper tightening se-
quence as shown.
h. Put a mark on the corner “1” of the bolt (cyl- inder head) and the cylinder head “2” as
shown.
New
1 2
2
4
3
1
3 4
2
2
4
Bolt “1”–“4”
1st
30 Nm (3.0 m·kgf, 22 ft·lbf)
Bolt “1”–“4” 2nd
20 Nm (2.0 m·kgf, 14 ft·lbf)
T R..
15
6
42
3
FWD
x2 x4
T R..
1
2

CYLINDER HEAD
6-22
i. Retighten the cylinder head mounting bolts
150° in the proper tightening sequence.
TIP
Tighten the bolts in two steps (90° and 60°) to
reach the specified angle in the proper tighten-
ing sequence.
j. Tighten the bolts to the specified torque.
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Bolt “1”–“4” Final
Specified angle 150°
Bolt “5”, “6” 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
T R..