warning YAMAHA WR 450F 2016 Service Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2016, Model line: WR 450F, Model: YAMAHA WR 450F 2016Pages: 426, PDF Size: 10.86 MB
Page 179 of 426
REAR BRAKE
5-27
EAS2GC1181INTRODUCTIONEWA
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 internal
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.
EAS2GC1182CHECKING THE REAR BRAKE DISC
1. Remove: • Rear wheel
Refer to “REAR WHEEL” on page 5-9.
2. Check: • Brake disc
Damage/galling Replace.
3. Measure: • Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification Replace.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 5-17.
4. Measure: • Brake disc deflection
Out of specification Correct the brake disc
deflection or replace the brake disc. 5. Adjust:
• Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Turn the mounted position of the brake disc by one bolt hole.
c. Install the brake disc.
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:• Rear wheel
Refer to “REAR WHEEL” on page 5-9.
Brake disc thickness limit
3.5 mm (0.14 in)
Brake disc runout limit (as mea-
sured on wheel) 0.15 mm (0.0059 in)
Brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf)
LOCTITE®
T R..
Page 180 of 426
REAR BRAKE
5-28
EAS2GC1183REMOVING THE REAR 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.
EAS2GC1184DISASSEMBLING THE REAR BRAKE CALI-
PER
1. Remove:
• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seal “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.
b. Remove the brake caliper piston dust seal and the brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1185CHECKING THE REAR 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 bracket
Crack/damage Replace.
EAS2GC1186ASSEMBLING THE REAR BRAKE CALIPEREWA
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.
2 3
1
Specified brake fluid
DOT 4
1
2
3
Page 181 of 426
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
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Page 182 of 426
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
Page 183 of 426
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..
Page 184 of 426
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
Page 187 of 426
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)
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Page 188 of 426
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”
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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..
Page 190 of 426
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
Page 194 of 426
FRONT FORK
5-42
EAS2GC1198REMOVING THE FRONT FORK LEGS
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Record the adjusting screw setting position be-
fore loosening the adjuster and the base valve.
2. Loosen:• Upper bracket pinch bolts
• Damper assembly
• Lower bracket pinch bolts
EWA
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
TIP
Before removing the front fork leg from the ve-
hicle, loosen the damper assembly “1” with the
cap bolt ring wrench “2”.
3. Remove:• Front fork leg (s)
EAS2GC1199DISASSEMBLING THE FRONT FORK LEGS
1. Drain:
• Fork oil
2. Remove:
• Adjuster “1”(from the inner tube)
TIP
• While compressing the inner tube “2”, set the cap bolt ring wrench “4” between the inner
tube and locknut “3”.
• Hold the locknut and remove the adjuster.
ECA
NOTICE
Do not remove the locknut as the damper
rod may go into the damper assembly and
not be taken out.
3. Remove:
• Dust seal “1”
• Oil seal clip “2”(with a flat-head screwdriver)
ECA
NOTICE
Do not scratch the inner tube.
4. Remove:
• Inner tube “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push in slowly “a” the inner tube just before it bottoms out and then pull it back quickly
“b”.
b. Repeat this step until the inner tube can be pulled out from the outer tube.
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench YM-01501
1 2
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench YM-01501
1
23
4
1
2