2004 YAMAHA WR 450F REAR WHEEL

5 - 20
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Disc cover 1
Bolt (disc cover) 2
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Install:
Caliper 1
Rear wheel 2
Refer to “FRONT WHEEL AND REAR
WHEEL” section.
4. Tighten:
Pad pin 3
5. Install:
Pad pin plug 4
Master cylinder kit
1. Clean:
Master cylinder
Master cylinder kit
Clean them with brake fluid.
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)
2. Install:
Master cylinder cup (primary) 1
Master cylinder cup (secondary) 2
To master cylinder piston 3.
NOTE:
Apply the brake fluid on the master cylinder
cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
ÅFront
ıRear
Åı
Åı

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CHASFRONT BRAKE AND REAR BRAKE
4. Install:
Pin 1
Plain washer 2
Cotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
New
Front brake hose
1. Install:
Brake hose 1
To brake hose holder 2.
NOTE:
Before tightening the bolt (brake hose holder),
align the top a of the brake hose neck with the
brake hose holder bottom b. Then pass the
brake hose in front of the axle boss c and fit it
into the hose groove d so that the brake hose
does not contact the nut (wheel axle).
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
2. Install:
Hose cover 1
Plain washer 2
Bolt [hose cover (M8)] 3
Bolt [hose cover (M6)] 4
T R..16 Nm (1.6 m · kg, 11 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
3. Pass the brake hose through the hose
guide 1, then through the guide a on
the protector 2.

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CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is no
danger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Headlight
Handlebar Refer to “HANDLEBAR” section.
1 Protector 1
2 Brake hose holder 2
3 Pinch bolt (handle crown) 2 Only loosening.
4 Cap bolt 1Loosen when disassembling the front fork.
5 Pinch bolt (under bracket) 2 Only loosening.
6 Front fork 1
1

7 - 16
TUN
EC72B000
Rear suspension setting
The rear suspension setting should be made
depending on the rider’s feeling of an actual
run and the circuit conditions.
The rear suspension setting includes the fol-
lowing two factors:
1. Setting of spring preload
Change the set length of the spring.
Change the spring.
2. Setting of damping force
Change the rebound damping.
Change the compression damping.
EC72C001
Choosing set length
1. Place a stand or block under the engine
to put the rear wheel above the floor, and
measure the length a between the rear
wheel axle center and the rear fender
holding bolt.
2. Remove the stand or block from the
engine and with a rider astride the seat,
measure the sunken length b between
the rear wheel axle center and the rear
fender holding bolt.
3. Loosen the locknut 1 and make adjust-
ment by turning the spring adjuster 2 to
achieve the standard figure from the sub-
traction of the length b from the length
a.
Standard figure:
90 ~ 100 mm (3.5 ~ 3.9 in)
SETTING