drain bolt YAMAHA YZ450F 2016 User Guide

CHASSIS
3-25
2. Replace:
• Brake pads
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a. Remove the pad pin plug “1”.
b. Loosen the pad pin “2”.
c. Remove the brake caliper “3” from the front
fork.
d. Remove the pad pin and brake pads “4”.
e. Connect the plastic hose “5” to the bleed
screw “6” and place a container under the
end of the plastic hose.f. Loosen the bleed screw and push the brake
caliper piston in.
EWA
WARNING
Do not reuse the drained brake fluid.
g. Tighten the bleed screw.
h. Install the brake pads “7” and the pad pin.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
i. Install the brake caliper “8” and tighten the
pad pin “9”.
j. Install the pad pin plug “10”.
1
3
2
4
6
5
Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Bolt (brake caliper)
28 Nm (2.8 m·kgf, 20 ft·lbf)
Pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
T R..
7
a b
T R..
8
9
T R..

CHASSIS
3-27
f. Loosen the bleed screw and push the brake
caliper piston in.
EWA
WARNING
Do not reuse the drained brake fluid.
g. Tighten the bleed screw.
h. Install the brake pad “10” and the pad pin
“11”.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.
i. Install the brake caliper “12” and the rear
wheel “13”.
Refer to “REAR WHEEL” on page 4-7.
j. Tighten the pad pin “14”.
k. Install the pad pin plug “15” and the protector
“16”.
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3. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-27.
4. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-22.
EASB111095CHECKING THE REAR BRAKE PAD INSU-
LATOR
1. Remove:
• Brake pads
Refer to “REAR BRAKE” on page 4-22.
2. Check:
• Rear brake pad insulator “1”
Damage  Replace.
EASB111096CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle upright on a level surface.
TIP
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the brake
fluid reservoir is horizontal. Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Bolt (protector)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T R..
10 11
a
b
T R..
13
14
12
T R..
15
16

FRONT BRAKE
4-12
EASB111134
FRONT BRAKE
Removing the front brake caliper
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
1 Union bolt 1
2 Copper washers 2
3 Front brake hose 1
4 Brake pad pin plug 1
5 Brake pad pin 1
6 Brake pads 2
7 Brake pad spring 1
8 Front brake caliper assembly 1
9 Front brake caliper bracket 1
For installation, reverse the removal proce-
dure.
3
9
1
2
8
4
5 7
6
T.R.30 Nm (3.0 mlbf) kgf, 22 ft
T.R.28 Nm (2.8 mlbf) kgf, 20 ft
T.R.17 Nm (1.7 mlbf) kgf, 12 ft
T.R.2.5 Nm (0.25 mlbf) kgf, 1.8 ft
T.R.6 Nm (0.6 mlbf) kgf, 4.3 ft

FRONT BRAKE
4-14
Removing the front brake master cylinder
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
1 Brake lever 1
2 Union bolt 1
3 Copper washers 2
4 Front brake hose 1
5 Brake master cylinder reservoir cap 1
6 Brake master cylinder reservoir diaphragm 1
7 Front brake master cylinder float 1
8 Front brake master cylinder holder 1
9 Front brake master cylinder 1
For installation, reverse the removal proce-
dure.
5
6
7
23
48
9
1
T.R.30 Nm (3.0 mlbf) kgf, 22 ft
T.R.1.5 Nm (0.15 mlbf) kgf, 1.1 ft
T.R.6 Nm (0.6 mlbf) kgf, 4.3 ft
T.R.6 Nm (0.6 mlbf) kgf, 4.3 ft

FRONT BRAKE
4-16
EASB111135INTRODUCTIONEWA
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 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.
EASB111136CHECKING THE FRONT BRAKE DISC
1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-3.
2. Check:
• Front brake disc
Damage/galling  Replace.
3. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace.4. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-3.
EASB111137REMOVING THE FRONT 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.
EASB111138DISASSEMBLING THE FRONT BRAKE CAL-
IPER
1. Remove:
• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seals “3”
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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.
Brake disc thickness limit
2.5 mm (0.10 in)
3
2
1

FRONT BRAKE
4-19
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 3-22.
6. Check:
• Brake fluid level
The minimum level mark or below  Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-27.
7. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” on page 3-23.
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-22.
EASB111143REMOVING THE FRONT BRAKE MASTER
CYLINDER
TIP
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove:
• Union bolt
• Copper washers
• Brake hoses
TIP
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EASB111144CHECKING THE FRONT 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/scratches/wear  Replace.
3. Check:
• Brake master cylinder reservoir cap
4. Check:
• Brake hoses
Cracks/damage/wear  Replace.
EASB111145ASSEMBLING THE FRONT BRAKE MAS-
TER 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.
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.Specified brake fluid
DOT 4
1
2

REAR BRAKE
4-22
EASB111147
REAR BRAKE
Removing the rear brake caliper
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
1 Protector 1
2 Union bolt 1
3 Copper washers 2
4 Rear brake hose 1
5 Brake pad pin plug 1
6 Brake pad pin 1
7 Rear brake pad assembly 2
8 Rear brake caliper bracket 1
9 Brake pad springs 2
10 Rear brake disc cover 1
11 Rear brake caliper assembly 1
For installation, reverse the removal proce-
dure.
2
3
4 11
56
79
1
8
9 10
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)T.R.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)T.R.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)T.R.
17 Nm (1.7 m•kgf, 12 ft•Ibf)T.R.
30 Nm (3.0 m•kgf, 22 ft•Ibf)T.R.
New
S
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)T.R.

REAR BRAKE
4-24
Removing the rear brake master cylinder
Order Part name Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-22.
1 Union bolt 1
2 Copper washers 2
3 Brake hose 1
4 Split pin 1
5Washer 1
6Pin 1
7 Brake master cylinder reservoir cap 1
8 Brake master cylinder reservoir diaphragm plate 1
9 Brake master cylinder reservoir diaphragm 1
10 Rear brake master cylinder 1
For installation, reverse the removal proce-
dure.
1
2
3
4 7
5 8
6 9
T R..
T R..
10
T R..

REAR BRAKE
4-26
EASB111148INTRODUCTIONEWA
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.
EASB111149CHECKING THE REAR BRAKE DISC
1. Remove:
• Rear wheel
Refer to “REAR WHEEL” on page 4-7.
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 4-16.
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.
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6. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-7. 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..

REAR BRAKE
4-27
EASB111150REMOVING 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.
EASB111151DISASSEMBLING 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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EASB111152CHECKING 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.
EASB111153ASSEMBLING 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