2004 YAMAHA WR 450F lock

5 - 33
CHASFRONT FORK
5. Install:
Spring guide 1
Locknut 2
To damper rod 3.
NOTE:
Install the spring guide with its cut a facing
upward.
With its thread b facing upward, fully finger
tighten the locknut onto the damper rod.
6. Install:
Dust seal 1
Stopper ring 2
Oil seal 3
Plain washer 4
Slide metal 5
To inner tube 6.
NOTE:
Apply the fork oil on the inner tube.
When installing the oil seal, use vinyl seat a
with fork oil applied to protect the oil seal lip.
Install the oil seal with its manufacture’s
marks or number facing the axle holder side.
New
New
7. Install:
Piston metal 1
NOTE:
Install the piston metal onto the slot on inner
tube.
New
8. Install:
Outer tube 1
To inner tube 2.

5 - 37
CHASFRONT FORK
21. Measure:
Distance a
Out of specification → Turn into the
locknut.
Distance a:
20 mm (0.79 in) or more
Between damper rod 1 top and
locknut 2 top.
22. Loosen:
Rebound damping adjuster 1
NOTE:
Loosen the rebound damping adjuster finger
tight.
Record the set position of the adjuster (the
amount of turning out the fully turned in posi-
tion).
23. Install
Cushion rubber 1
Washer 2
Spacer 3
To cap bolt 4.
NOTE:
Install the cushion rubber with its smaller
dia.end a facing the cap bolt.
24. Install:
Push rod 1
Fork spring 2
NOTE:
Install the fork spring with the damper rod 3
pulled up.
After installing the fork spring, hold the
damper rod end so that it will not go down.
25. Install:
Cap bolt 1
Fully tighten the cap bolt onto the
damper rod by hand.

5 - 38
CHASFRONT FORK
26. Tighten:
Cap bolt (locknut) 1
NOTE:
While compressing the fork spring, set the
thin type spanners 2 between the spacer 3
and spring guide 4.
Hold the locknut 5 and tighten the cap bolt
with specified torque.
27. Install:
Cap bolt 1
To outer tube.
NOTE:
Temporarily tighten the cap bolt.
T R..29 Nm (2.9 m · kg, 21 ft · lb)
28. Install:
Protector guide 1
Installation
1. Install:
Front fork 1
NOTE:
Temporarily tighten the pinch bolts (under
bracket).
Do not tighten the pinch bolts (handle crown)
yet.
2. Tighten:
Cap bolt 1
3. Adjust:
Front fork top end a
Front fork top end (standard) a:
Zero mm (Zero in)
T R..30 Nm (3.0 m · kg, 22 ft · lb)

5 - 47
CHAS
ETAPES DE SERRAGE:
Serrer l’écrou annulaire à un couple d’environ. 38 Nm (3,8 m · kg, 27 ft · lb)
Le desserrer d’un tour.
Le resserrer à un couple d’environ. 7 Nm (0,7 m · kg, 5,1 ft · lb)
Organisation de la dépose Ordre Nom de pièce QtéRemarques
11 Roulement (supérieur) 1
12 Roulement (inférieur) 1
Se reporter à “POINTS DE DEPOSE”.
13 Cage à billes 2
2
ANZUGSREIHENFOLGE:
Ringmutter mit 38 Nm (3,8 m · kg, 27 ft · lb) festziehen.
Um eine Umdrehung lockern.
Nochmals mit 7 Nm (0,7 m • kg, 5,1 ft · lb) festziehen.
Demontage-ArbeitenReihen-
folgeBauteil Anz. Bemerkungen
11 Lager (oben) 1
12 Lager (unten) 1
Siehe unter “AUSBAU”.
13 Laufring 2
2
PASOS DE APRIETE:
Apriete la tuerca de anilla. 38 Nm (3,8 m · kg, 27 ft · lb)
Aflójela con un giro.
Apriétela nuevamente. 7 Nm (0,7 m · kg, 5,1 ft · lb)
Alcance de la extracción Orden Denominación de la pieza Cantidad Observaciones
11 Cojinete (superior) 1
12 Cojinete (inferior) 1
Consulte el apartado “PUNTOS DE EXTRACCIÓN”.
13 Guía de bolas 2
2
DIRECTION
LENKKOPF
DIRECCIÓN

5 - 50
CHAS
4. Install:
Plain washer 1
Ring nut 2
Tighten the ring nut using the ring nut
wrench 3.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
5. Check the steering shaft by turning it lock
to lock. If there is any binding, remove the
steering shaft assembly and inspect the
steering bearings.
6. Install:
Plain washer 1
7. Install:
Front fork 1
Handle crown 2
Main switch 3
Coupler bracket 4
Hose guide bracket 5
NOTE:
Install the coupler bracket on the outside of
the hose guide bracket.
Temporarily tighten the pinch bolts (under
bracket).
Do not tighten the pinch bolts (handle crown)
yet.
8. Install:
Plain washer 1
Steering shaft nut 2
T R..145 Nm (14.5 m · kg, 105 ft · lb)
STEERING

5 - 61
CHASREAR SHOCK ABSORBER
Extent of removal Order Part name Q’ty Remarks
Disconnect the starter relay cou-
pler.
Starter motor lead Disconnect at the starter relay side.
1 Locking tie 2
2 Taillight coupler 1
3 Starting circuit cut-off relay cou-
pler1
4 Plastic band 2
5 Clamp (air filter joint) 1 Only loosening.
6 Rear frame 1
7 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
8 Bolt (rear shock absorber-frame) 1
9 Rear shock absorber 1
10 Locknut 1 Only loosening.
11 Adjuster 1 Only loosening.
12 Spring guide (lower) 1
13 Spring guide (upper) 1
2
1

5 - 61
CHAS
Organisation de la dépose Ordre Nom de pièce QtéRemarques
Débrancher le Raccord du relais de démarreur.
Câble de démarreur Débrancher du côté du relais de démarreur.
1 Attache 2
2 Raccord de feu arrière 1
3 Raccord du relais de coupe-circuit de démar-
rage 1
4 Bande en plastique 2
5 Bride (raccord de filtre à air) 1 Desserrer uniquement.
6 Cadre arrière 1
7 Boulon (amortisseur arrière-bras de relais) 1 Tenir le bras oscillant.
8 Boulon (amortisseur arrière-cadre) 1
9 Amortisseur arrière 1
10 Contre-écrou 1 Desserrer uniquement.
11 Dispositif de réglage 1 Desserrer uniquement.
12 Guide de ressort (inférieur) 1
13 Guide de ressort (supérieur) 1
1
2
Demontage-ArbeitenReihen-
folgeBauteil Anz. Bemerkungen
Den Starterrelais-Leitungsstecker abtren-
nen.
Startermotorleitung An der Starterrelais-Seite abtrennen.
1 Sperrband 2
2 Heckleuchten-Leitungsstecker 1
3 Starterkreis-Unterbrecherrelaisstecker 1
4 Plastikbinder 2
5 Schlauchschelle (Luftfilteranschluß) 1 Nur lockern.
6 Rahmenhinterteil 1
7 Schraube (Umlenkhebel, Federbein) 1 Die Schwinge festhalten.
8 Schraube (Federbein, Rahmen) 1
9 Federbein 1
10 Sicherungsmutter 1 Nur lockern.
11 Einstellmutter 1 Nur lockern.
12 Federsitz (unten) 1
13 Federsitz (oben) 1
1
2
Alcance de la extracción Orden Denominación de la pieza Cantidad Observaciones
Desconecte el acoplador del relé del arrancador.
Cable del motor de arranque Desconecte en el lado del relé del arrancador.
1 Conexión plástica de cierre 2
2 Acoplador de la luz de cola 1
3 Acoplador del relé interruptor del circuito de
encendido1
4 Banda plástica 2
5 Abrazadera (junta del depurador de aire) 1 Aflojándolo únicamente.
6 Bastidor trasero 1
7 Perno (amortiguador trasero-brazo intermedio) 1 Sujete la palanca oscilante.
8 Perno (amortiguador trasero-bastidor) 1
9 Amortiguador trasero 1
10 Contratuerca 1 Aflojándolo únicamente.
11 Ajustador 1 Aflojándolo únicamente.
12 Guía del resorte (inferior) 1
13 Guía del resorte (superior) 1
1
2
AMORTISSEUR ARRIERE
FEDERBEIN
AMORTIGUADOR TRASERO

5 - 66
CHASREAR SHOCK ABSORBER
2. Tighten:
Adjuster 1
3. Adjust:
Spring length (installed) a
* For EUROPE, AUS, NZ and ZA
NOTE:
The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
CAUTION:
Never attempt to turn the adjuster beyond
the maximum or minimum setting.
Spring length (installed) a:
Standard
lengthExtent of
adjustment
245 mm (9.65 in)
* 247 mm (9.72 in)240.5 ~ 258.5 mm
(9.47 ~ 10.18 in)
4. Tighten:
Locknut 1
Rear shock absorber
1. Install:
Dust seal 1
O-ring 2
Collar 3
NOTE:
Apply the molybdenum disulfide grease on
the bearing.
Apply the lithium soap base grease on the
dust seals, O-rings and collars.
New