brake YAMAHA WR 450F 2016 Service Manual

REAR WHEEL
5-11
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
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EAS2GC1165ASSEMBLING THE REAR WHEEL
1. Install:• Bearing (right side) “1”
• Circlip “2”
• Spacer “3”
• Bearing (left side) “4”
• Oil seals “5”
TIP
• Apply the lithium-soap-based grease to the bearing and the oil seal lip when installing.
• Install the bearing with seal facing outward.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s
marks or numbers facing outward.
ECA
NOTICE
Install the bearing by pressing its outer race
parallel.
TIP
Use a socket “1” that matches the diameter of
the bearing outer race and that of the oil seal. 2. Install:
• Brake disc “1”
• Brake disc bolt “2”
TIP
Tighten the bolts in stages and in a crisscross
pattern.
3. Install:• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
EAS2GC1166INSTALLING THE REAR WHEEL
1. Install:
• Rear wheel
New
New
5
43
1
25
LSLS
Brake disc bolt
14 Nm (1.4 m·kgf, 10 ft·lbf)
LOCTITE®
1
T R..
1
LS

REAR WHEEL
5-12
TIP
Install the brake disc “1” between the brake
pads “2” correctly.
2. Install:• Drive chain “1”
TIP
Push the rear wheel “2” forward and install the
drive chain.
3. Install:• Left drive chain puller “1”
• Rear wheel axle “2”
TIP
• Install the left drive chain puller, and insert the rear wheel axle from the left side.
• Apply the lithium-soap-based grease to the
rear wheel axle.
4. Install: • Right drive chain puller “1”
• Washer “2”
• Rear wheel axle nut “3”
TIP
Temporarily tighten the nut (rear wheel axle) at
this point.
5. Adjust:
• Drive chain slack “a”
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-31.
6. Tighten: • Rear wheel axle nut “1”
• Locknut “2”
Drive chain slack (on a suitable
stand) 50.0–60.0 mm (1.97–2.36 in)
Wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf)
Locknut 21 Nm (2.1 m·kgf, 15 ft·lbf)
2
1
3
a
T R..
T R..
1
2

FRONT BRAKE
5-13
EAS2GC1167
FRONT BRAKE
Removing the front brake caliper
OrderPart name Q’tyRemarks
Brake fluid Drain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-25.
1 Union bolt 1
2 Copper washers 2
3 Front brake hose 1
4 Brake pad pin plug 1
5 Brake pad pin 1
6 Brake pads 2
7 Brake pad spring 1
8 Front brake caliper assembly 1
9 Front brake caliper bracket 1
For installation, reverse the removal proce-
dure.
3
9
1
2
8
4
5
7
6
T.R.30 Nm (3.0 mlbf)
kgf, 22 ft
T.R.23 Nm (2.3 mlbf)
kgf, 17 ft
T.R.17 Nm (1.7 mlbf)
kgf, 12 ft
T.R.2.5 Nm (0.25 mlbf)
kgf, 1.8 ft
T.R.6 Nm (0.6 mlbf)
kgf, 4.3 ft

FRONT BRAKE
5-14
Disassembling the front brake caliper
OrderPart name Q’tyRemarks
1 Brake caliper piston 2
2 Brake caliper piston dust seal 2
3 Brake caliper piston seal 2
4 Bleed screw 1
For assembly, reverse the disassemble pro-
cedure.
1 2
34
S
S
BF
BFT R..
S
6 Nm (0.6 m kgf, 4.3 ft Ibf)

FRONT BRAKE
5-15
Removing the front brake master cylinder
OrderPart name Q’tyRemarks
Brake fluid Drain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-25.
1 Brake lever 1
2 Union bolt 1
3 Copper washers 2
4 Front brake hose 1
5 Brake master cylinder reservoir cap 1
6 Brake master cylinder reservoir diaphragm 1
7 Front brake master cylinder float 1
8 Front brake master cylinder holder 1
9 Front brake master cylinder 1
For installation, reverse the removal proce-
dure.
5
6
7
2 3
4 8
9
1
T.R.30 Nm (3.0 mlbf)
kgf, 22 ft
T.R.1.5 Nm (0.15 mlbf)
kgf, 1.1 ft
T.R.6 Nm (0.6 mlbf)
kgf, 4.3 ft
T.R.6 Nm (0.6 mlbf)
kgf, 4.3 ft

FRONT BRAKE
5-16
Disassembling the front brake master cylinder
OrderPart name Q’tyRemarks
1 Push rod 1
2 Dust boot 1
3 Circlip 1
4Washer 1
5 Brake master cylinder kit 1
For assembly, reverse the disassemble pro-
cedure.
BF
5
4
3
2
1
S
New
New

FRONT BRAKE
5-17
EAS2GC1168INTRODUCTIONEWA
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components unless absolutely necessary.
• If there is any problem with connections on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the
brake fluid, and clean it. After that, add a
suitable amount of brake fluid. Then, bleed
it after reassembly.
• Use only brake fluid for washing brake
components.
• Use new brake fluid for cleaning the brake components.
• Immediately wipe off the spilled brake fluid to avoid damage to painted surfaces or
plastic parts.
• Handle brake fluid with special care not to let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS2GC1169CHECKING THE FRONT BRAKE DISC
1. Remove: • Front wheel
Refer to “FRONT WHEEL” on page 5-4.
2. Check: • Front brake disc
Damage/galling  Replace.
3. Measure: • Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace. 4. Install:
• Front wheelRefer to “FRONT WHEEL” on page 5-4.
EAS2GC1170REMOVING THE FRONT BRAKE CALIPER
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:• Union bolt
• Copper washers
• Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid.
EAS2GC1171DISASSEMBLING THE FRONT BRAKE CAL-
IPER
1. Remove:• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seals “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening to force out the piston from the
brake caliper.
EWA
WARNING
• Cover the brake caliper piston with a rag. Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
Brake disc thickness limit 2.5 mm (0.10 in)
3
2
1

FRONT BRAKE
5-18
b. Remove the brake caliper piston dust seal and the brake caliper piston seal.
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EAS2GC1172CHECKING THE FRONT BRAKE CALIPER
1. Check:
• Brake caliper piston “1”Rust/scratches/wear  Replace the brake
caliper piston.
• Brake caliper cylinder “2” Scratches/wear  Replace the brake cali-
per assembly.
• Brake caliper body “3” Cracks/damage  Replace the brake cali-
per assembly.
• Brake fluid delivery passages (brake caliper body)
Obstruction  Blow out with compressed
air.
EWA
WARNING
When the brake caliper is disassembled, re-
place the brake caliper piston seal and the
brake caliper piston dust seal with new
ones.
2. Check: • Brake caliper bracketCrack/damage  Replace.
EAS2GC1173ASSEMBLING THE FRONT BRAKE CALI-
PER
EWA
WARNING
• Before installation, clean and lubricate the
internal parts. Use new brake fluid for
cleaning and lubricating.
• Never use solvents on internal brake com- ponents as they will cause the piston seals
to swell and distort.
• When the brake caliper is disassembled, replace the brake caliper piston seal and
the brake caliper piston dust seal with new
ones.
EAS2GC1174INSTALLING 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 seal and the brake caliper piston dust seal into the grooves in the
brake caliper correctly.
2
113
Specified brake fluidDOT 4
New
New
1
1
2 2

FRONT BRAKE
5-19
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.
EAS2GC1175INSTALLING THE FRONT BRAKE CALIPER
1. Install:• Front brake caliper bracket
• Front brake caliper(temporarily)
• 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 “a” of the
brake hose touches the projection “b” on
the brake caliper. 2. Install:
• Front brake caliper
• Brake pad spring
• Brake pad
• Brake pad pin
• Brake hose holder
Refer to “CHECKING THE FRONT BRAKE
PADS” on page 3-27.
3. Tighten: • Brake hose holder nut “1”
TIP
Make sure that the brake hose holder “2” is in-
stalled with its upper end “a” aligned with the
paint “b” on the brake hose.
4. Pour brake fluid to the brake master cylinder 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
Front brake caliper bracket23 Nm (2.3 m·kgf, 17 ft·lbf)
Brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf)
1
a1
New
T R..
a
b
Brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake hose holder nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Specified brake fluid DOT 4
T R..
T R..
1
2
b
a

FRONT BRAKE
5-20
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:• Brake systemRefer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
6. Check: • Brake fluid level
The minimum level mark or below  Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30.
7. Check: • Brake lever free playRefer to “ADJUSTING THE FRONT
BRAKE” on page 3-26.
• Brake lever operation A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
EAS2GC1176REMOVING THE FRONT BRAKE MASTER
CYLINDER
TIP
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove: • Union bolt
• Copper washers
• Brake hoses
TIP
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EAS2GC1177CHECKING THE FRONT 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/scratches/wear  Replace.
3. Check: • Brake master cylinder reservoir cap
4. Check: • Brake hosesCracks/damage/wear  Replace.
EAS2GC1178ASSEMBLING THE FRONT BRAKE MAS-
TER 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.
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. Specified brake fluid
DOT 4
1
2