wheel YAMAHA YZ450F 2014 Owner's Manual

CHASSIS
3-33
2. Tighten:
• Spokes
Use a spoke nipple wrench “1” for tighten-
ing.
TIP
• Do not give a half turn (180°) or more for one
tightening.
• Make sure that tightening after a break-in is
done until the initial looseness in nipples dis
-
appears.
• Make sure that tightening is done in stages,
not at a time.
EAS1SL1109CHECKING THE WHEELS
1. Check:
• Wheel (s)
Damage/out-of-round  Replace.EWA13260
WARNING
Never attempt to make any repairs to the
wheel.
TIP
After replacing a tire or a wheel, always bal-
ance the wheel.
EAS1SL1110CHECKING THE WHEEL BEARINGS
1. Check:
• Wheel bearings
“CHECKING THE FRONT WHEEL” on page
4-4and “CHECKING THE REAR WHEEL”
on page 4-8.
EAS1SL1111
CHECKING AND ADJUSTING THE STEER-
ING HEAD
1. Use a suitable stand to raise the front wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  Adjust the steering
head.
3. Remove:
• Handlebar
Refer to “HANDLEBAR” on page 4-31.
• Upper bracket
Refer to “STEERING HEAD” on page 4-49.
4. Adjust:
• Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the washer “1.”
b. After loosening the ring nut “2” with a steer-
ing nut wrench “3,” tighten it to the specified
torque.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly.
Spoke nipple wrench (6–7)
90890-01521
YM-01521
Spokes
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
1
T R..
1

4
CHASSIS
GENERAL CHASSIS........................................................................................ 4-1
REMOVING THE LEFT SIDE COVER ....................................................... 4-2
REMOVING THE SEAT ............................................................................. 4-2
REMOVING THE NUMBER PLATE ........................................................... 4-2
FRONT WHEEL................................................................................................ 4-3
REMOVING THE FRONT WHEEL............................................................. 4-4
CHECKING THE FRONT WHEEL ............................................................. 4-4
DISASSEMBLING THE FRONT WHEEL ................................................... 4-5
ASSEMBLING THE FRONT WHEEL ......................................................... 4-5
INSTALLING THE FRONT WHEEL ........................................................... 4-6
REAR WHEEL.................................................................................................. 4-7
REMOVING THE REAR WHEEL ............................................................... 4-8
CHECKING THE REAR WHEEL................................................................ 4-8
DISASSEMBLING THE REAR WHEEL ..................................................... 4-8
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ............ 4-8
ASSEMBLING THE REAR WHEEL ........................................................... 4-9
INSTALLING THE REAR WHEEL.............................................................. 4-9
FRONT BRAKE.............................................................................................. 4-11
INTRODUCTION ...................................................................................... 4-15
CHECKING THE FRONT BRAKE DISC .................................................. 4-15
REMOVING THE FRONT BRAKE CALIPER ........................................... 4-15
DISASSEMBLING THE FRONT BRAKE CALIPER................................. 4-15
CHECKING THE FRONT BRAKE CALIPER ........................................... 4-16
ASSEMBLING THE FRONT BRAKE CALIPER ....................................... 4-16
INSTALLING THE BRAKE CALIPER PISTON ........................................ 4-16
INSTALLING THE FRONT BRAKE CALIPER ......................................... 4-17
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................ 4-18
CHECKING THE FRONT BRAKE MASTER CYLINDER......................... 4-18
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER .................... 4-18
INSTALLING THE FRONT BRAKE MASTER CYLINDER....................... 4-19
REAR BRAKE................................................................................................ 4-21
INTRODUCTION ...................................................................................... 4-25
CHECKING THE REAR BRAKE DISC..................................................... 4-25
REMOVING THE REAR BRAKE CALIPER ............................................. 4-26
DISASSEMBLING THE REAR BRAKE CALIPER ................................... 4-26
CHECKING THE REAR BRAKE CALIPER .............................................. 4-26
ASSEMBLING THE REAR BRAKE CALIPER ......................................... 4-26
INSTALLING THE BRAKE CALIPER PISTON ........................................ 4-27
INSTALLING THE REAR BRAKE CALIPER ............................................ 4-27
REMOVING THE REAR BRAKE MASTER CYLINDER .......................... 4-28
CHECKING THE REAR BRAKE MASTER CYLINDER ........................... 4-28
ASSEMBLING THE REAR BRAKE MASTER CYLINDER....................... 4-29
INSTALLING THE REAR BRAKE MASTER CYLINDER ......................... 4-29

HANDLEBAR................................................................................................. 4-31
REMOVING THE HANDLEBAR............................................................... 4-33
CHECKING THE HANDLEBAR ............................................................... 4-33
INSTALLING THE HANDLEBAR ............................................................. 4-33
FRONT FORK................................................................................................. 4-37
REMOVING THE FRONT FORK LEGS ................................................... 4-39
DISASSEMBLING THE FRONT FORK LEGS ......................................... 4-39
CHECKING THE FRONT FORK LEGS ................................................... 4-40
ASSEMBLING THE FRONT FORK LEGS ............................................... 4-41
INSTALLING THE FRONT FORK LEGS ................................................. 4-47
STEERING HEAD........................................................................................... 4-49
REMOVING THE LOWER BRACKET...................................................... 4-50
CHECKING THE STEERING HEAD ........................................................ 4-50
INSTALLING THE STEERING HEAD ...................................................... 4-50
REAR SHOCK ABSORBER ASSEMBLY..................................................... 4-53
HANDLING THE REAR SHOCK ABSORBER ......................................... 4-56
DISPOSING OF A REAR SHOCK ABSORBER ...................................... 4-56
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................... 4-56
REMOVING THE BEARING..................................................................... 4-56
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................... 4-57
CHECKING THE CONNECTING ARM AND RELAY ARM ...................... 4-57
INSTALLING THE RELAY ARM............................................................... 4-57
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY .................. 4-58
SWINGARM.................................................................................................... 4-60
REMOVING THE SWINGARM................................................................. 4-61
REMOVING THE BEARING..................................................................... 4-61
CHECKING THE SWINGARM ................................................................. 4-61
INSTALLING THE SWINGARM ............................................................... 4-62
CHAIN DRIVE................................................................................................. 4-63
REMOVING THE DRIVE CHAIN.............................................................. 4-64
CHECKING THE DRIVE CHAIN .............................................................. 4-64
CHECKING THE DRIVE SPROCKET...................................................... 4-65
CHECKING THE REAR WHEEL SPROCKET ......................................... 4-65
INSTALLING THE DRIVE CHAIN ............................................................ 4-65

FRONT WHEEL
4-3
EAS1SL1122
FRONT WHEEL
Removing the front wheel
OrderPart nameQ’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
1Front wheel axle pinch bolt4Loosen.
2Front wheel axle nut1
3Front wheel axle1
4Front wheel1
5Collars2
6Oil seals2
7Bearing2
8Brake disc1
For installation, reverse the removal proce-dure.
12 Nm (1.2 mkgf, 8.7 ftIbf)T.R.
New
New
LT
LS
LS
LS
5
76
5 6 7
(6)
8
12
1 3
21 Nm (2.1 mkgf, 15 ftIbf)T.R.
21 Nm (2.1 mkgf, 15 ftIbf)T.R.
4
115 Nm (11.5 mkgf, 83 ftlbf)T.R.

FRONT WHEEL
4-4
EAS1SL1123REMOVING THE FRONT WHEEL
1. Use a suitable stand to raise the front wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Front wheel
EAS1SL1124CHECKING THE FRONT WHEEL
1. Check:
• Front wheel axle
Roll the front wheel axle on a flat surface.
Bends  Replace.
EWA13460
WARNING
Do not use a bent front wheel axle even after
correcting this.
2. Check:
•Tire (s)
• Front wheel
Damage/wear  Replace
Refer to “CHECKING THE TIRES” on page
3-32 and “CHECKING THE WHEELS” on
page 3-33.
3. Check:
• Spokes
Bend/damage  Replace.
Loose  Tighten.
Tap the spokes with a screwdriver.
TIP
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
4. Tighten:
• Spokes
Refer to “CHECKING AND TIGHTENING
THE SPOKES” on page 3-32.
TIP
After tightening the spokes, measure the wheel
runout.
5. Measure:
• Wheel radial runout “a”
• Wheel lateral runout “b”
Out of specification  Repair/replace.
6. Check:
•Collars
Damage/wear  Replace
7. Check:
• Bearing
Front wheel turns roughly or is loose  Re-
place the wheel bearings.
• Oil seals
Damage/wear  Replace
Spokes
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
T R..
ab

FRONT WHEEL
4-5
EAS1SL1125DISASSEMBLING THE FRONT WHEEL
1. Remove:
• Oil seals
• Bearing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel sur
-
face.
c. Remove the bearings with a bearing puller.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SL1126ASSEMBLING THE FRONT WHEEL
1. Install:
• Bearing (left side) “1”
• Spacer “2”
• Bearing (right side) “3”
• Oil seals “4”
TIP
• Apply the lithium soap base grease to the
bearing and the oil seal lip when installing.
• Left side of bearing shall be installed first.
• Install the oil seal with its manufacture's
marks or numbers facing outward.
ECA1DX1005
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.
12
New
Brake disc bolt
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
LOCTITE®
4
3
2
1
4
New
New
1
T R..

FRONT WHEEL
4-6
3. Install:
• Collar “1”
TIP
Apply the lithium soap base grease on the oil
seal lip.
EAS1SL1127INSTALLING THE FRONT WHEEL
1. Install:
• Front wheel
TIP
Install the brake disc “1” between the brake
pads “2” correctly.
2. Install:
• Front wheel axle “1”
TIP
Apply the lithium soap base grease to the front
wheel axle.
3. Tighten:
• Front wheel axle nut “1”
ECA14140
NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:
• Front wheel axle pinch bolt “1”
1
LS
Front wheel axle nut
115 Nm (11.5 m·kgf, 83 ft·lbf)
Front wheel axle pinch bolt
21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
1
T R..
1 1

REAR WHEEL
4-7
EAS1SL1128
REAR WHEEL
Removing the rear wheel
OrderPart nameQ’tyRemarks
Use a suitable stand to raise the rear wheel
off the ground.
1Nut (rear wheel axle)1
2Rear wheel axle1
3Drive chain puller2
4REAR WHEEL1
5Collars2
6Rear wheel sprocket1
7Oil seals2
8Circlip1
9Bearing3
10Brake disc1
For installation, reverse the removal proce-dure.
(6)
21 Nm (2.1 m•kgf, 15 ft•Ibf)T.R.
2 5
7 9
LS
LS(6)
46
1
(6) 3
LS
8
9 10
7 5
LT
14 Nm (1.4 m•kgf, 10 ft•Ibf)T.R.
3
21 Nm (2.1 m•kgf, 15 ft•Ibf)T.R.
42 Nm (4.2 m•kgf, 30 ft•Ibf)T.R.
135 Nm (13.5 m•kgf, 98 ft•lbf)T.R.

REAR WHEEL
4-8
EAS1SL1129REMOVING THE REAR WHEEL
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Rear wheel axle nut “1”
3. Loosen:
• Locknut “2”
4. Tighten:
• Adjusting bolt “3”
5. Remove:
• Rear wheel axle
• Rear wheel
TIP
• Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.
EAS1SL1130CHECKING THE REAR WHEEL
1. Check:
• Rear wheel axle
• Rear wheel
• Bearing
• Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.
2. Check:
•Tire (s)
• Rear wheel
Damage/wear  Replace
Refer to “CHECKING THE TIRES” on page
3-32 and “CHECKING THE WHEELS” on
page 3-33.
3. Check:
• Spokes
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.
4. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.
EAS1SL1131DISASSEMBLING THE REAR WHEEL
1. Remove:
• Oil seals
• Bearing
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-5.
EAS1SL1132CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth wear “a”  Replace the
rear wheel sprocket and the drive sprocket
as a set.
Bent tooth  Replace the rear wheel
sprocket and the drive sprocket as a set.
2. Replace:
• Rear wheel sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
3
12
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
b. Correct
1. Drive chain roller
2. Rear wheel sprocket
Rear wheel sprocket self-locking
nut
42 Nm (4.2 m·kgf, 30 ft·lbf)
T R..

REAR WHEEL
4-9
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SL1133ASSEMBLING 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 base 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.
ECA1DX1006
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 base grease on the oil
seal lip.
EAS1SL1134INSTALLING 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