warning YAMAHA YZ450F 2016 Service Manual

FRONT FORK
4-41
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5. Remove:
• Base valve “1”
(from the damper assembly)
TIP
Hold the damper assembly with the cap bolt
ring wrench “2” and use the cap bolt wrench “3”
to remove the base valve.
EASB111167CHECKING THE FRONT FORK LEGS
1. Check:
• Inner tube
Scratches  Repair or replace.
Use #1000 grit wet sandpaper.
Damaged oil lock piece  Replace.
• Outer tube
Out of specification  Replace.
Use the dial gauge “1”.
TIP
The bending value is shown by one half of the
dial gauge reading.
EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Check:
• Outer tube
Scratches/wear/damage  Replace.
3. Measure:
• Fork spring free length “a”
Out of specification  Replace.
4. Check:
• Damper rod “1”
Bend/damage  Replace.
• Damper rod “2”
Wear/damage  Replace.
ECA1DX1010
NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork. Cap bolt wrench
90890-01500
YM-01500
Cap bolt ring wrench
90890-01501
YM-01501
Inner tube bending limit
0.2 mm (0.01 in)
1 23
Fork spring free length
497.0 mm (19.57 in)
Limit
492.0 mm (19.37 in)

FRONT FORK
4-42
5. Check:
• Base valve “1”
Wear/damage  Replace.
Contamination  Clean.
• O-rings “2”
Wear/damage  Replace.
• Base valve bushing “3”
Wear/damage  Replace.
• Spring “4”
Damage/fatigue  Replace the base valve.
• Air bleed screw “5”
Wear/damage  Replace.
6. Check:
• Contacting surface “a”
Wear/damage  Replace.
7. Check:
• Adjuster “1”
• O-rings “2”
Wear/damage  Replace.EASB111168ASSEMBLING THE FRONT FORK LEGSEWA13660
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
• Inner tube bushing
• Outer tube bushing
• Oil seals
• Copper washers
• Before assembling the front fork leg, make
sure that all of the components are clean.
1. Stretch the damper assembly fully.
2. Fill:
• Damper assembly
ECA14210
NOTICE
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
fork performance.
• When disassembling and assembling the
front fork leg, take care not to allow any
foreign material to enter the front fork.
3. After filling, pump the damper assembly “1”
slowly up and down (about 200 mm (7.9 in)
stroke) several times to bleed the damper
assembly of air.
TIP
Avoid excessive full stroke. A stroke of 200 mm
(7.9 in) or more will cause air to enter. In this
case, repeat the steps 1 to 3.
21
New
New
New
2
21 543
a
New
Recommended oil
Suspension oil S1
Standard oil amount
204 cm
3 (6.90 US oz, 7.20
Imp.oz)
New
1
2

FRONT FORK
4-49
2. Tighten:
• Damper assembly “1”
TIP
Use the cap bolt ring wrench “2” to tighten the
damper assembly.
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. Damper assembly
30 Nm (3.0 m·kgf, 22 ft·lbf)
Cap bolt ring wrench
90890-01501
YM-01501
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)
T R..
2
1
a
T R..
T R..
Bolt (protector)
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
21
T R..
1
2
1

STEERING HEAD
4-52
EASB111171REMOVING THE LOWER BRACKET
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.
2. Remove:
• Rng nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.
EWA
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EASB111172CHECKING THE STEERING HEAD
1. Wash with kerosene:
• Bearing
• Bearing races
2. Check:
• Bearing
• Bearing races
Damage/pitting  Replace.
3. Replace:
• Bearing
• Bearing races
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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.
ECA
NOTICE
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.
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4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EASB111173INSTALLING THE STEERING HEAD
1. Install:
• Lower bearing “1”
TIP
Apply the lithium-soap-based grease on the
dust seal lip and bearing inner circumference. Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

STEERING HEAD
4-54
8. Install:
• Steering stem nut “1”
TIP
Apply the lithium-soap-based grease to the
contact surface of the steering stem nut when
installing.
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

REAR SHOCK ABSORBER ASSEMBLY
4-58
EASB111175HANDLING THE REAR SHOCK ABSORBEREWA
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure that you understand the following in-
formation. The manufacturer cannot be held
responsible for property damage or person-
al injury that may result from improper han-
dling of the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.
EASB111176DISPOSING OF A REAR SHOCK ABSORB-
ER
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA
WARNING
• Wear protective glasses to prevent your
eyes from damage due to possible gas or
metal chips scattered.
• To dispose of a damaged or a worn-out
rear shock absorber, take the unit to your
Yamaha dealer for this disposal proce-
dure.
EASB111177REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Rear shock absorber assembly lower bolt
“1”
TIP
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly
1
1

SWINGARM
4-63
EASB111184REMOVING THE SWINGARM
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Measure:
• Swingarm side play
• Swingarm vertical movement
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a. Measure the tightening torque of the pivot
shaft nut.
b. Measure the swingarm side play “a” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
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EASB111185REMOVING THE BEARING
1. Remove:
• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EASB111186CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage  Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check:
• Oil seals
Damage  Replace.
• Bearing
• Spacers
Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set. Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial)
1.0 mm (0.04 in)
T R..

CHAIN DRIVE
4-66
EASB111189REMOVING THE DRIVE CHAIN
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:
• Joint clip
• Drive chain joint “1”
• Drive chain “2”
EASB111190CHECKING THE DRIVE CHAIN
1. Measure:
• 15-link section of the drive chain
Out of specification  Replace the drive
chain.
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a. Measure the length “a” between the inner
sides of the pins and the length “b” between
the outer sides of the pins on a 15-link sec-
tion of the drive chain as shown in the illus-
tration.
b. Calculate the length “c” of the 15-link section
of the drive chain using the following formu-
la.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
TIP
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a differ-
ent location each time.
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2. Check:
•Drive chain
Stiffness  Clean, lubricate, or replace.
3. Clean:
•Drive chain
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a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
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15-link length limit
242.9 mm (9.56 in)

CHAIN DRIVE
4-67
4. Check:
• Drive chain rollers “1”
Damage/wear  Replace the drive chain.
• Drive chain side plates “2”
Damage/wear  Replace the drive chain.
5. Lubricate:
•Drive chain
EASB111191CHECKING THE DRIVE SPROCKET
1. Check:
• Drive sprocket
More than 1/4 tooth wear “a”  Replace the
drive sprocket and the rear wheel sprocket
as a set.
Bent tooth  Replace the drive sprocket
and the rear wheel sprocket as a set.
EASB111192CHECKING THE REAR WHEEL SPROCKET
Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-8.
EASB111193
INSTALLING THE DRIVE CHAIN
1. Install:
• Drive chain “1”
• Drive chain joint “2”
• Joint clip “3”
EWA
WARNING
When installing the joint clip, always keep
the direction as shown in the figure.
2. Lubricate:
•Drive chain
3. Install:
• Drive sprocket
• Lock washer
• Drive sprocket nut
Refer to “ENGINE REMOVAL” on page 5-1.
ECA1DX1014
NOTICE
Never install a new drive chain onto worn
drive sprockets; this will dramatically short-
en the drive chain’s life.
4. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-28.
ECA13550
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
b. Correct
1. Drive chain roller
2. Drive sprocket
Drive sprocket nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
Drive chain slack
50–60 mm (1.97–2.36 in)
New
New
T R..

TRANSMISSION
5-73
EASB111288REMOVING THE TRANSMISSION
1. Remove:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Shift cam “3”
• Shift fork 3 “4”
• Shift fork 2 “5”
• Shift fork 1 “6”
• Main axle “7”
• Drive axle “8”
• Collar “9”
TIP
• Remove assembly with the collar “9” installed
to the crankcase.
• Make a note of the position of each part. Pay
particular attention to the location and direc-
tion of shift forks.
• Remove the main axle and the drive axle all
together by tapping the drive axle lightly with
a soft hammer.
EASB111289
CHECKING THE SHIFT FORKS
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear  Replace the
shift fork.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement  Replace the shift forks
and shift fork guide bar as a set.
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4
62
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3
8
7
9