Front YAMAHA YZ450F 2014 Repair Manual

FRONT FORK
4-48
3. Adjust:
• Front fork top end “a”
4. Tighten:
• Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA33DD044
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:
• Protector “1”
• Bolt (protector) “2”
6. Adjust:
• Rebound damping force
TIP
Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position.
7. Adjust:
• Compression damping force
TIP
Turn in the damping adjuster “1” finger-tight
and then turn out to the originally set position.
Front fork top end (standard) “a”
0 mm (0 in)
Upper bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Bolt (protector)
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
a
T R..
T R..
21
T R..
1
2
1
1

STEERING HEAD
4-49
EAS1SL1171
STEERING HEAD
Removing the lower bracket
OrderPart nameQ’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Number plateRefer to “GENERAL CHASSIS” on page 4-1.
HandlebarRefer to “HANDLEBAR” on page 4-31.
1Front fender1
2Steering stem nut1
3Front fork leg (s)2Refer to “FRONT FORK” on page 4-37.
4Upper bracket1
5Steering ring nut1
6Lower bracket1
7Bearing race cover1
8Upper bearing1
9Bearing (lower side)1
10Bearing races2
For installation, reverse the removal proce-dure.
2
4
5
7
3
1
6
8
9
10
LS
1st
2ndT.R.
LS
LS
T.R.21 Nm (2.1 mlbf) kgf, 15 ft
T.R.9 Nm (0.9 mlbf) kgf, 6.5 ft
T.R.21 Nm (2.1 mlbf) kgf, 15 ft
T.R.10 Nm (1.0 mlbf) kgf, 7.2 ft
T.R.145 Nm (14.5 mlbf) kgf, 105 ft
38 Nm (3.8 m
lbf) kgf, 27 ft
7 Nm (0.7 m
lbf) kgf, 5.1 ft

STEERING HEAD
4-50
EAS1SL1172REMOVING THE LOWER BRACKET
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:
• Ring nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS1SL1173CHECKING THE STEERING HEAD
1. Wash with kerosene:
• Bearing
• Bearing races
2. Check:
• Bearing
• Bearing races
Damage/pitting  Replace.
3. Replace:
• Bearing
• Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing race from the steering
head pipe with a long rod “1” and a hammer.
b. Remove the bearing race from the lower
bracket with a chisel “2” and a hammer.
c. Install a new bearing race.ECA14270
NOTICE
• Take care not to damage the steering shaft
thread.
• If the bearing race is not installed properly,
the steering head pipe could be damaged.
TIP
Always replace the bearing and the bearing
race as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAS1SL1174INSTALLING THE STEERING HEAD
1. Install:
• Lower bearing “1”
TIP
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

STEERING HEAD
4-51
2. Install:
• Bearing races
• Upper bearing “1”
• Bearing race cover “2”
TIP
Apply the lithium soap base grease on the
bearing and bearing race cover lip.
3. Install:
• Lower bracket “1”
TIP
Apply the lithium soap base 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 3-33.
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.
Steering ring nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LS
1 a
LSLS
T R..

STEERING HEAD
4-52
8. Install:
• Steering stem nut “1”
TIP
Apply the lithium soap base grease to the con-
tact surface of the steering stem nut when in-
stalling.
9. After tightening the nut, check the steering
for smooth movement. If not, adjust the
steering by loosening the steering ring nut
little by little.
10.Adjust:
• Front fork top end “a”
11.Tighten:
• Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA33DD049
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.Steering stem nut
145 Nm (14.5 m·kgf, 105 ft·lbf)
Front fork top end (standard) “a”
0 mm (0 in)
T R..
a
Upper bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts
21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
T R..
21

SWINGARM
4-60
EAS1SL1184
SWINGARM
Removing the swingarm
OrderPart nameQ’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Brake hose holderRefer to “REAR BRAKE” on page 4-21.
Rear brake caliperRefer to “REAR BRAKE” on page 4-21.
Bolt (brake pedal)
Drive chain
1Collars2
2Oil seals2
3Thrust bearing2
4Bushing2
5Oil seals2
6Bearing4
For installation, reverse the removal proce-dure.
1
2
3
6
4
6
4
1
3
6
2
5
T.R.70 Nm (7.0 mlbf) kgf, 51 ft
T.R.4.0 Nm (0.40 mlbf) kgf, 2.9 ft

ENGINE REMOVAL
5-3
Removing the electronic parts
OrderPart nameQ’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
SeatRefer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right)Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left / right)Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tankRefer to “FUEL TANK” on page 7-1.
Air filter case cover
1Rectifier/regulator1
2ECU1
3Ignition coil1
4Condenser1
5Neutral switch1
6AC magneto lead1Disconnect.
7Crankshaft position sensor coupler1Disconnect.
8Coolant temperature sensor coupler1Disconnect.
For installation, reverse the removal proce-dure.
T.R.
T.R.
T.R.T.R.
8 3
7
6
154
2
LT

ENGINE REMOVAL
5-4
Removing the engine
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 4-1.
Rear fender Refer to “GENERAL CHASSIS” on page 4-1
Fuel tank Refer to “FUEL TANK” on page 7-1.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 5-1.
Air filter case Refer to “THROTTLE BODY” on page 7-5.
Throttle body Refer to “THROTTLE BODY” on page 7-5.
Clutch cable Refer to “CLUTCH” on page 5-37.
Shift pedal Refer to “SHIFT SHAFT” on page 5-49.
1 Engine guard 1
2 Brake pedal 1
3Spring 1
4 Cylinder head breather hose 1
5 Drive sprocket cover 1
6 Drive chain guide 1
New
New
LS
M
8
8
76
11
4 5
New
1
10
3 2

ENGINE REMOVAL
5-8
3. Replace:• Fiber “1”
4. Install: • Silencer body “1”
•Bolt “2”
TIP
Apply heat-resistant sealant to the areas “a”
shown, making sure that there are no gaps in
the beads of sealant.
5. Replace:• Fiber “1”
TIP
Stuff the fiber into the silencer body by using a
flat board “2”.
6. Install:• Silencer cap “1”
•Rivet “2”
TIP
• Apply heat-resistant sealant to the areas “a” shown, making sure that there are no gaps in
the beads of sealant.
• Take care not to allow the fiber out of place
when installing the silencer body “3”.
EAS1SL1203INSTALLING THE ENGINE
1. Install: • Engine “1”Install the engine from the right side.
• Pivot shaft “2”
• Engine mounting bolt (lower side) “3”
• Front engine bracket “4”
• Engine bracket bolt (front side) “5”
• Engine mounting bolt (front side) “6”
• Upper engine bracket “7”
• Engine bracket bolt (upper side) “8”
• Engine mounting bolt (upper side) “9”
TIP
Apply molybdenum disulfide grease to the pivot
shaft.
Silencer body bolt
8 Nm (8.0 m·kgf, 5.8 ft·lbf)
LOCTITE®
1
T R..
a
1 2LT
2
1
Pivot shaft85 Nm (8.5 m·kgf, 61 ft·lbf)
Engine mounting bolt (lower side) 53 Nm (5.3 m·kgf, 38 ft·lbf)
Engine bracket bolt (front side) 34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine mounting bolt (front side) 59 Nm (5.9 m·kgf, 43 ft·lbf)
Engine bracket bolt (upper side) 34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine mounting bolt (upper
side) 45 Nm (4.5 m·kgf, 33 ft·lbf)
1
1
a233
T R..
T R..
T R..
T R..
T R..
T R..

ENGINE REMOVAL
5-10
EAS1SL1206INSTALLING THE EXHAUST PIPE AND
MUFFLER
1. Install:
•Gasket
• Exhaust pipe 1 “1”
• Nut (exhaust pipe 1) “2”
TIP
First temporarily tighten 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).
2. Install:
•Clamp
• Exhaust pipe 2 “1”
• Bolt (exhaust pipe 2) “2”
TIP
Install and temporarily tighten the exhaust pipe
2 with its end positioned as shown with respect
to the exhaust pipe 1.
3. Install:
•Clamp
• Silencer “1”
• Bolt (silencer) “2”
TIP
Install and temporarily tighten the silencer so
that its joint is positioned as shown with respect
to the exhaust pipe 2.
4. Tighten:
• Bolt (exhaust pipe 2)
•Clamp
TIP
Tighten while checking that their front and rear
joints are inserted in position.
Nut (exhaust pipe)
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
New
T R..
1
22
1
2
2mm (0.08in)
Bolt (silencer)
30 Nm (3.0 m·kgf, 22 ft·lbf)
Bolt (exhaust pipe 2)
20 Nm (2.0 m·kgf, 14 ft·lbf)
Clamp
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T R..
2
2
1
2mm (0.08in)
T R..
T R..