ECU YAMAHA YZ450F 2009 User Guide

5-29
STEERING
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE STEERING RING
NUT
1. Remove:
• Steering ring nut "1"
Use the steering nut wrench "2".
Support the steering stem so that
it may not fall down.
REMOVING THE LOWER
BEARING
1. Remove:
• Lower bearing "1"
Use the floor chisel "2".
Take care not to damage the steer-
ing shaft thread.
REMOVING THE BEARING RACE
1. Remove:
• Bearing race "1"
Remove the bearing race using
long rod "2" and the hammer.
CHECKING THE STEERING STEM
1. Inspect:
• Steering stem "1"
Bend/damage→Replace.CHECKING THE BEARING AND
BEARING RACE
1. Wash the bearings and bearing
races with a solvent.
2. Inspect:
• Bearing "1"
• Bearing race
Pitting/damage→Replace bear-
ings and bearing races as a set.
Install the bearing in the bearing
races. Spin the bearings by hand.
If the bearings hang up or are not
smooth in their operation in the
bearing races, replace bearings
and bearing races as a set.
INSTALLING THE LOWER
BRACKET
1. Install:
• Lower bearing "1"
Apply the lithium soap base grease
on the dust seal lip and bearing inner
circumference.
2. Install:
• Bearing race
• Upper bearing "1"
• Bearing race cover "2"
Apply the lithium soap base grease
on the bearing and bearing race cov-
er lip.
3. Install:
• Lower bracket "1"
Apply the lithium soap base grease
on the bearing, the portion "a" and
thread of the steering stem.
4. Install:
• Steering ring nut "1"
Tighten the steering ring nut using
the steering nut wrench "2".
Refer to "CHECKING AND AD-
JUSTING THE STEERING
HEAD" section in the CHAPTER
3.
5. Check the steering stem by turn-
ing it lock to lock. If there is any
binding, remove the steering stem
assembly and inspect the steer-
ing bearings.
6. Install:
• Washer "1" Steering nut wrench:
YU-33975/90890-01403
Steering ring nut:
7 Nm (0.7 m•kg, 5.1 ft•
lb)

5-33
SWINGARM
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE BEARING
1. Remove:
• Bearing "1"
Remove the bearing by pressing its
outer race.
CHECKING THE SWINGARM
1. Inspect:
• Bearing "1"
• Bushing "2"
Free play exists/unsmooth revolu-
tion/rust →Replace bearing and
bushing as a set.
2. Inspect:
•Oil seal "3"
Damage→Replace.
CHECKING THE RELAY ARM
1. 5294Inspect:
• Bearing "1"
•Collar "2"
Free play exists/unsmooth revolu-
tion/rust → Replace bearing and
collar as a set.
2. Inspect:
•Oil seal "3"
Damage→Replace.
CHECKING THE CONNECTING
ROD
1. Inspect:
• Bearing "1"
•Collar "2"Free play exists/unsmooth revolu-
tion/rust →Replace bearing and
collar as a set.
2. Inspect:
• Oil seal "3"
Damage→Replace.
INSTALLING THE BEARING AND
OIL SEAL
1. Install:
• Bearing "1"
• Oil seal "2"
To swingarm.• Apply the molybdenum disulfide
grease on the bearing when install-
ing.
• Install the bearing by pressing it on
the side having the manufacture's
marks or numbers.
• First install the outer and then the
inner bearings to a specified depth
from inside.
2. Install:
• Bearing "1"
•Washer "2"
• Oil seal "3"
To relay arm.
• Apply the molybdenum disulfide
grease on the bearing when install-
ing.• Install the bearing by pressing it on
the side having the manufacture's
marks or numbers.
• Apply the molybdenum disulfide
grease on the washer.
3. Install:
• Bearing "1"
•Oil seal "2"
To connecting rod.
• Apply the molybdenum disulfide
grease on the bearing when install-
ing.
• Install the bearing by pressing it on
the side having the manufacture's
marks or numbers.
INSTALLING THE SWINGARM
1. Install:
• Bushing "1"
• Thrust bearing "2"
•Oil seal "3"
•Collar "4"
To swingarm "5".
Apply the molybdenum disulfide
grease on the bushings, thrust bear-
ings, oil seal lips and contact surfaces
of the collar and thrust bearing.
Installed depth of bear-
ings:
Outer "a": Zero mm
(Zero in)
Inner "b": 6.5 mm (0.26
in)
Installed depth of bear-
ings "a":
Zero mm (Zero in)
Installed depth of bear-
ings "a":
Zero mm (Zero in)

5-37
REAR SHOCK ABSORBER
HANDLING NOTE
• Support the machine securely so
there is no danger of it falling
over.
• This rear shock absorber is pro-
vided with a separate type tank
filled with high-pressure nitro-
gen gas. To prevent the danger
of explosion, read and under-
stand the following information
before handling the shock ab-
sorber. The manufacturer can
not be held responsible for prop-
erty damage or personal injury
that may result from improper
handling.
• Never tamper or attempt to dis-
assemble the cylinder or the
tank.
• Never throw the rear shock ab-
sorber into an open flame or
other high heat. The rear shock
absorber may explode as a re-
sult of nitrogen gas expansion
and/ or damage to the hose.
• Be careful not to damage any
part of the gas tank. A damaged
gas tank will impair the damp-
ing performance or cause a
malfunction.
• Take care not to scratch the
contact surface of the piston
rod with the cylinder; or oil
could leak out.
• Never attempt to remove the
plug at the bottom of the nitro-
gen gas tank. It is very danger-
ous to remove the plug.
• When scrapping the rear shock
absorber, follow the instruc-
tions on disposal.
NOTES ON DISPOSAL (YAMAHA
DEALERS ONLY)
Before disposing the rear shock ab-
sorber, be sure to extract the nitrogen
gas from valve "1". Wear eye protec-
tion to prevent eye damage from es-
caping gas and/or metal chips.
To dispose of a damaged or worn-
out rear shock absorber, take the
unit to your Yamaha dealer for this
disposal procedure.
REMOVING THE BEARING
1. Remove:
• Stopper ring (upper bearing) "1"
Press in the bearing while pressing its
outer race and remove the stopper
ring.
2. Remove:
• Upper bearing "1"
Remove the bearing by pressing its
outer race.
3. Remove:
• Lower bearing "1"
Remove the bearing by pressing its
outer race.
CHECKING THE REAR SHOCK
ABSORBER
1. Inspect:
• Damper rod "1"
Bends/damage→Replace rear
shock absorber assembly.
• Shock absorber "2"
Oil leaks→Replace rear shock
absorber assembly.
Gas leaks→Replace rear shock
absorber assembly.• Spring "3"
Damage→Replace spring.
Fatigue→Replace spring.
Move spring up and down.
• Spring guide "4"
Wear/damage→Replace spring
guide.
• Spring seat "5"
Cracks/damage →Replace.
• Bearing "6"
Free play exists/unsmooth revolu-
tion/rust →Replace.
INSTALLING THE BEARING
1. Install:
• Upper bearing "1"
Install the bearing parallel until the
stopper ring groove appears by
pressing its outer race.
Do not apply the grease on the
bearing outer race because it will
wear the rear shock absorber sur-
face on which the bearing is press
fitted.
2. Install:
• Stopper ring (upper bearing) "1"
After installing the stopper ring, push
back the bearing until it contacts the
stopper ring.