lock YAMAHA WR 450F 2016 Service Manual

FRONT FORK
5-45
4. Measure:• Oil level (left and right) “a”
Out of specification  Regulate.
5. Tighten: • Locknut “1”
TIP
Fully finger tighten the locknut onto the damper
assembly. 6. Loosen:
• Compression damping force adjuster “1”
TIP
• Before loosening the damping force adjuster, record the setting position.
• Unless the damping force adjuster is fully loosened, correct damping characteristic can-
not be obtained after installation.
7. Install: • Base valve “1”(to the damper assembly “2”)
TIP
First bring the damper rod pressure to a maxi-
mum. Then install the base valve while releas-
ing the damper rod pressure.
8. Check:• Damper assembly
Not fully stretched  Repeat the steps 1 to
7.
Standard oil level
145–148 mm (5.71–5.83 in)
From top of fully stretched
damper assembly.
1
a1
1
2

FRONT FORK
5-48
19.Install:• Oil seal clip “1”
TIP
Fit the oil seal clip correctly in the groove in the
outer tube.
20.Install:
• Dust seal “1”
TIP
Apply lithium-soap-based grease on the inner
tube.
21.Check:• Inner tube smooth movementTightness/binding/rough spots  Repeat
the steps 14 to 20. 22.Measure:
• Distance “a”
Out of specification  Turn into the locknut.
23.Install: • Collar “1”
• Fork spring “2”(to the damper assembly “3”)
TIP
Install the collar with its larger dia. end “a” fac-
ing the fork spring.
New
Distance “a”16 mm (0.63 in) or more
Between the damper assembly
“1” bottom and locknut “2” bot-
tom.
1 2a
12
3 a

FRONT FORK
5-49
24.Install:• Damper assembly “1”(to the inner tube “2”)
ECA
NOTICE
Allow the damper assembly to slide slowly
down the inner tube until it contacts the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
25.Loosen:
• Rebound damping force adjuster “1”
TIP
• Before loosening the damping force adjuster, record the setting position.
• Unless the damping force adjuster is fully loosened, correct damping characteristic can-
not be obtained after installation.
26.Install: • Damper adjusting rod “1”
• Copper washer “2”
• Adjuster “3”(to the damper assembly “4”)
TIP
• While compressing the inner tube “5”, set the cap bolt ring wrench “7” between the inner
tube and locknut “6”.
• Fully finger tighten the adjuster onto the
damper assembly. 27.Measure:
• Gap “a” between the adjuster “1” and the
locknut “2”
Out of specification  Retighten and read-
just the locknut.
TIP
If it is installed with a gap out of specification,
correct damping force cannot be obtained.
28.Tighten:
• Adjuster (locknut) “1”
TIP
Hold the locknut “2” and tighten the adjuster.
1
2
1
New
Cap bolt ring wrench90890-01501
Cap bolt ring wrench YM-01501
Gap “a” between the adjuster and
the locknut 0.5–1.0 mm (0.02–0.04 in)
Adjuster (locknut) 29 Nm (2.9 m·kgf, 21 ft·lbf)
1
2 a
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STEERING HEAD
5-56
TIP
Apply the lithium-soap-based grease on the
bearing and bearing race cover lip.
3. Install:• Lower bracket “1”
TIP
Apply the lithium-soap-based grease on the
bearing, the portion “a” and thread of the steer-
ing stem.
4. Install:• Steering ring nut “1”
TIP
Install the steering nut with its stepped side “a”
facing downward.
Tighten the steering ring nut with a steering
nut wrench “2”.
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-37. 5. Check the steering stem by turning this lock
to lock. If there is any binding, remove the
steering stem and check the steering bear-
ing.
6. Install: • Washer “1”
7. Install: • Front fork “1”
• Upper bracket “2”
TIP
• Temporarily tighten the pinch bolts (lower bracket).
• Do not tighten the pinch bolts (upper bracket)
yet.
8. Install: • Steering stem nut “1”
Steering ring nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LS
1
a
LSLS
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Steering stem nut
145 Nm (14.5 m·kgf, 105 ft·lbf)
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REAR SHOCK ABSORBER ASSEMBLY
5-58
EAS2GC1207
REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly
OrderPart name Q’tyRemarks
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
1 Rear shock absorber assembly lower bolt 1
2 Rear shock absorber assembly upper bolt 1
3 Rear shock absorber assembly 1
4 Locknut 1
5 Adjusting nut 1
6 Lower spring guide 1
7 Upper spring guide 1
8Spring 1
9 Dust seal 2
10 Collars 2
11 Bushing 1
2
12
1615
14 13
12
14
4
5
7
6
8 3
9
9
10
10
11
1
New
New
13New
LS
LS
M
M
M
M
M

CHAIN DRIVE
5-71
c. After riveting, make sure the space “c”, which is inside of the connecting link “3” and
inside of the connecting plate “1”, is 14.1–
14.3 mm (0.56–0.65 in).
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2. Lubricate:
•Drive chain
3. Install: • Drive sprocket
• Lock washer
• Drive sprocket nutRefer to “ENGINE REMOVAL” on page 6-1.
ECA
NOTICE
Never install a new drive chain onto worn
drive chain sprockets; this will dramatically
shorten the drive chain’s life.
4. Adjust:• Drive chain slackRefer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-31.
ECA
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
Recommended lubricant Chain lubricant suitable for O-
ring chains
Drive sprocket nut 75 Nm (7.5 m·kgf, 54 ft·lbf)
Drive chain slack (on a suitable
stand) 50.0–60.0 mm (1.97–2.36 in)
New
T R..

ENGINE REMOVAL
6-6
EAS2GC1227REMOVING THE SILENCER
1. Remove:• Rear shock absorber assembly lower bolt “1”
• Connecting arm bolt (relay arm side) “2”
• Silencer “3”
TIP
Move the rear shock absorber to the left side of
the chassis, and remove the silencer.
EAS2GC1228REMOVING THE EXHAUST PIPE 2
1. Remove: • Starter motor
Refer to “ELECTRIC STARTER” on page 6-
36.
• Exhaust pipe 2
TIP
Put the Exhaust pipe 2 into the state as shown
by moving this, and then remove it.
EAS2GC1229REMOVING THE DRIVE SPROCKET
1. Straighten the lock washer tab.
2. Remove:
• Nut (drive sprocket) “1”
• Lock washer “2”
TIP
Loosen the nut while applying the rear brake.
3. Remove:• Drive sprocket “1”
• Drive chain “2”
TIP
Remove the drive sprocket together with the
drive chain.
1 2
3

ENGINE REMOVAL
6-9
EAS2GC1234INSTALLING THE BRAKE PEDAL
1. Install:• Spring “1”
• Brake pedal “2”
• O-rings “3”
• Bolt (brake pedal) “4”
•Clip “5”
TIP
Apply the lithium-soap-based grease on the
bolt, O-rings and brake pedal bracket.
EAS2GC1235INSTALLING THE DRIVE SPROCKET
1. Install:• Drive sprocket “1”
• Drive chain “2”
TIP
Install the drive sprocket together with the drive
chain.
2. Install:• Lock washer “1”
• Nut (drive sprocket) “2”
TIP
Tighten the nut while applying the rear brake.
ECA
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is
fastened together.
3. Bend the lock washer tab to lock the nut.
4. Install:• Drive sprocket guide
• Drive sprocket cover “1”
• Bolt (drive sprocket cover) “2”
EAS2GC1236INSTALLING THE EXHAUST PIPE AND
MUFFLER
1. Install:•Gasket
• Exhaust pipe 1 “1”
• Nut (exhaust pipe 1) “2”
TIP
First temporarily tighten all nuts to 7 Nm (0.7
m·kgf, 5.1 ft·lbf). Then retighten them to 10 Nm
(1.0 m·kgf, 7.2 ft·lbf).
Bolt (brake pedal)
26 Nm (2.6 m·kgf, 19 ft·lbf)
Nut (drive sprocket) 75 Nm (7.5 m·kgf, 54 ft·lbf)
New
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1
2
3 4 5
LS
New
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Bolt (drive sprocket cover)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Nut (exhaust pipe) 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
2 1
New
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CAMSHAFT
6-13
EAS2GC1238REMOVING THE CAMSHAFT
1. Remove:• Timing mark accessing screw “1”
• Crankshaft end accessing screw “2”
2. Align: • Alignment mark
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a. Turn the crankshaft counterclockwise with a
wrench.
b. Align the top dead center (TDC) mark “a” on the rotor with the alignment mark “b” on the
crankcase cover.
TIP
Align the alignment ma rk “c” on the exhaust
camshaft sprocket and the alignment mark “d”
on the intake camshaft sprocket with the edge
of the cylinder head.
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3. Remove: • Timing chain tensioner cap bolt “1”
• Timing chain tensioner “2”
•Gaskets 4. Remove:
• Bolt (camshaft cap) “1”
• Camshaft cap “2”
• Clip “3”
TIP
• Remove the bolts (camshaft cap) in a criss-
cross pattern, working from the outside in.
• In order to prevent the clip from falling into the
crankcase, remove the camshaft cap.
ECA
NOTICE
The bolts (camshaft cap) must be removed
evenly to prevent damage to the cylinder
head, camshafts or camshaft caps.
5. Remove:
• Exhaust camshaft “1”
• Intake camshaft “2”
TIP
Attach a wire “3” to the timing chain to prevent
it from falling into the crankcase.
12
ab
d
c
1
2
1
2
3

CAMSHAFT
6-15
c. Install the dowel pins and the camshaft caps.
TIP
• Tighten the camshaft cap bolts in a crisscross pattern from innermost to outer caps.
• Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance.
d. Remove the camshaft caps and then mea- sure the width of the Plastigauge® “1”.
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5. Measure:• Camshaft journal diameter “a”Out of specification  Replace the cam-
shaft.
Within specification  Replace the cylinder
head and the camshaft caps as a set.
EAS2GC1240CHECKING THE TIMING CHAIN AND CAM-
SHAFT SPROCKET
1. Check: • Timing chain “1”
Damage/stiffness  Replace the timing
chain and camshaft as a set. 2. Check:
• Camshaft sprocketMore than 1/4 tooth wear “a”  Replace the
camshaft and the timing chain as a set.
EAS2GC1241CHECKING THE TIMING CHAIN TENSION-
ERS
1. Check: • Timing chain tensioner
Crack/damage  Replace.
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a. While pressing the tensioner rod lightly with
your fingers, use a thin screwdriver “1” to
wind the tensioner rod up fully clockwise.
b. When releasing the screwdriver by pressing lightly with your fingers, make sure that the
tensioner rod will come out smoothly.
c. If not, replace the tensioner assembly.
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Camshaft cap bolts 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Camshaft journal diameter 21.959–21.972 mm (0.8645–
0.8650 in)
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1
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
a
b 1
2