2004 YAMAHA WR 450F oil

5 - 3
CHAS

ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
RUEDA DELANTERA Y RUEDA TRASERA
AUSBAU
Hinterrad
1. Demontieren:

Rad
1

HINWEIS:

Das Rad nach vorne stoßen und die
Antriebskette
2
abnehmen.
Radlager (nach Bedarf)
1. Demontieren:

Lager
1

HINWEIS:

Die Lager mit einem Lageraustreiber
2
ausbauen.
PRÜFUNG
Rad
1. Messen:

Felgenschlag
Unvorschriftsmäßig
→

Instand setzen/Erneuern.
Max. Felgenschlag:
Höhenschlag
1
:
2,0 mm (0,08 in)
Seitenschlag
2
:
2,0 mm (0,08 in)
2. Kontrollieren:

Lager
Den inneren Laufring mit
dem Finger drehen.
Schwergängigkeit/Freßspu-
ren
→
Erneuern.
HINWEIS:

Lager, Dichtringe und Hülse im Satz
erneuern.
POINTS DE DEPOSE
Roue arrière
1. Déposer:

Roue
1

N.B.:

Pousser la roue vers l’avant et déposer la
chaîne de transmission
2
.
Roulement de roue (si nécessaire)
1. Déposer:

Roulement
1
N.B.:

Déposer le roulement en utilisant un
arrache-roulement courant 2.
CONTROLE
Roue
1. Mesure:
Voile de roue
Hors limite → Réparer/chan-
ger.
Limite de voile de la roue:
Radial 1:
2,0 mm (0,08 in)
Latéral 2:
2,0 mm (0,08 in)
2. Contrôler:
Roulement
Faire tourner la bague inté-
rieure avec le doigt.
Point dur/grippage → Changer.
N.B.:
Changer à la fois les roulements, la
bague d’étanchéité et la collerette de
roue.PUNTOS DE EXTRACCIÓN
Rueda trasera
1. Extraer:
Rueda 1
NOTA:
Empuje la rueda hacia delante y extraiga
la cadena de transmisión 2.
Cojinete de la rueda (en caso necesa-
rio)
1. Extraer:
Cojinete 1
NOTA:
Extraiga el cojinete con un extractor de
cojinetes universal 2.
INSPECCIÓN
Rueda
1. Medir:
Excentricidad de la rueda
Fuera del límite → Reparar/
reemplazar.
Límite de excentricidad de
la rueda:
Radial 1:
2,0 mm (0,08 in)
Lateral 2:
2,0 mm (0,08 in)
2. Inspeccionar:
Cojinete
Gire la pista interna con un
dedo.
Superficie áspera/agarrota-
miento → Reemplazar.
NOTA:
Reemplace los cojinetes, el retén de
aceite y el casquillo de la rueda como un
juego.

5 - 4
CHAS
ROUE AVANT ET ROUE ARRIERE
VORDER- UND HINTERRAD
RUEDA DELANTERA Y RUEDA TRASERA
Radachse
1. Messen:
Radachsschlag
Unvorschriftsmäßig →
Erneuern.
Die Meßuhr 1 verwenden.
HINWEIS:
Der Radachsschlag entspricht der
Hälfte der Meßuhranzeige.
WARNUNG
Nie versuchen, eine verbogene
Achse zu richten.
Max. Radachsschlag:
0,5 mm (0,020 in)
Bremsscheibe
1. Messen:
Bremsscheibenschlag
Die Meßuhr 1 verwenden.
Unvorschriftsmäßig → Fel-
genschlag prüfen.
Falls im Sollbereich, die
Bremsscheibe erneuern.
2. Messen:
Bremsscheibenstärke a
Unvorschriftsmäßig →
Erneuern.
Max. Bremsscheiben-
verzug:
Standard
Hin-
ten—0,15 mm
(0,006 in)
Bremsscheiben-Min-
deststärke:
Standard
Vorn3,0 mm
(0,12 in)2,5 mm
(0,10 in)
Hin-
ten4,0 mm
(0,16 in)3,5 mm
(0,14 in)
Axe de roue
1. Mesurer:
Les flexions de l’axe de roue
Hors-spécification → Changer.
Utiliser le comparateur 1.
N.B.:
La valeur de flexion est égale à la moitié
de la lecture du comparateur.
AVERTISSEMENT
Ne jamais tenter de redresser un axe
tordu.
Limite de torsion de l’axe
de roue:
0,5 mm (0,020 in)
Disque de frein
1. Mesurer:
Déflexion de disque de frein
Utiliser le comparateur 1.
Hors spécification → Exami-
ner le voile de roue.
Si le voile de la roue est nor-
mal, changer le disque de frein.
2. Mesurer:
Epaisseur de disque de frein a
Hors limite → Changer.
Limite de déflexion de dis-
que:
Standard
Arriè-
re—0,15 mm
(0,006 in)
Limite d’usure de disque:
Standard
Avant3,0 mm
(0,12 in)2,5 mm
(0,10 in)
Arriè-
re4,0 mm
(0,16 in)3,5 mm
(0,14 in)
Eje de la rueda
1. Medir:
Deformaciones del eje de la
rueda
Fuera de especificaciones →
Reemplazar.
Utilice el calibre de cuadrantes
1.
NOTA:
El valor de deformación se indica como
la mitad del valor de la lectura del cali-
bre de cuadrantes.
ADVERTENCIA
No intente enderezar un eje doblado.
Límite de deformación del
eje de la rueda:
0,5 mm (0,020 in)
Disco del freno
1. Medir:
Desviación del disco del freno
Utilice el calibre de cuadrantes
1.
Fuera de especificaciones →
Comprobar la excentricidad de
la rueda.
Si la excentricidad de la rueda
está en buen estado, reemplace
el disco del freno.
2. Medir:
Espesor del disco del freno a
Fuera del límite → Reempla-
zar.
Límite de desviación del
disco:
Estándar
Tra-
sero—0,15 mm
(0,006 in)
Límite de desgaste del
disco:
Estándar
Delan-
tero3,0 mm
(0,12 in)2,5 mm
(0,10 in)
Tra-
sero4,0 mm
(0,16 in)3,5 mm
(0,14 in)

5 - 5
CHAS

FRONT WHEEL AND REAR WHEEL
EC595000
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:

Bearing (left)
1


Spacer
2


Bearing (right)
3


Oil seal
4

NOTE:


Apply the lithium soap base grease on the
bearing and oil seal lip when installing.

Use a socket that matches the outside diam-
eter of the race of the bearing.

Left side of bearing shall be installed first.

Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer

race.
2. Install:
Brake disc 1
Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
New
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Install the collar with their projection a fac-
ing the wheel.
4. Install:
Trip meter gear unit 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip of the trip meter gear unit.
Make sure the two projections a in the
wheel hub are meshed with the two slots b
in the trip meter gear unit.
b a1
B

5 - 8
CHAS
Rear wheel
1. Install:
Bearing (right) 1
Circlip 2
Spacer 3
Bearing (left) 4
Oil seal 5
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Install the bearing with seal facing outward.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Right side of bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
New
New
2. Install:
Brake disc 1
Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..14 Nm (1.4 m · kg, 10 ft · lb)
3. Install:
Driven sprocket 1
Bolt (driven sprocket) 2
Plain washer (driven sprocket) 3
Nut (driven sprocket) 4
NOTE:
Tighten the nuts in stage, using a crisscross
pattern.
T R..50 Nm (5.0 m · kg, 36 ft · lb)
FRONT WHEEL AND REAR WHEEL

5 - 9
CHASFRONT WHEEL AND REAR WHEEL
4. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
5. Install:
Wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.
6. Install:
Drive chain 1
NOTE:
Push the wheel 2 forward and install the drive
chain.
7. Install:
Chain puller (left) 1
Wheel axle 2
NOTE:
Install the chain puller (left), and insert the
wheel axle from left side.
Apply the lithium soap base grease on the
wheel axle.
8. Install:
Chain puller (right) 1
Plain washer 2
Nut (wheel axle) 3
NOTE:
Temporarily tighten the nut (wheel axle) at this
point.

5 - 25
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Brake hose holder 1
Screw (brake hose holder) 2
CAUTION:
After installing the brake hose holders,
make sure the brake hose does not contact
the spring (rear shock absorber). If it does,
correct its twist.
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
Brake fluid
1. Fill:
Brake fluid
Until the fluid level reaches “LOWER”
level line a.
WARNING
Use only the designated quality brake
fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
Refill with the same type of brake fluid;
mixing fluids may result in a harmful chem-
ical reaction and lead to poor performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in vapor lock.
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
ÅFront
ıRear
Recommended brake fluid:
DOT #4
Å
ı

5 - 28
CHASFRONT FORK
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:1 Oil seal removal2 Damper rod removal
Extent of removal Order Part name Q’ty Remarks
FRONT FORK DISASSEMBLY
1 Cap bolt 1 Refer to “REMOVAL POINTS”.
2 Fork spring 1 Drain the fork oil.
3 Dust seal 1
Refer to “REMOVAL POINTS”. 4 Stopper ring 1
5 Inner tube 1
6 Outer tube 1
7 Piston metal 1
8 Slide metal 1
9 Plain washer 1
0 Oil seal 1
A Spring guide 1
B Base valve 1 Use special tool.
C Damper rod 1 Refer to “REMOVAL POINTS”.
1
2

5 - 29
CHASFRONT FORK
EC556000
HANDLING NOTE
NOTE:
The front fork requires careful attention. So it is
recommended that the front fork be main-
tained at the dealers.
CAUTION:
To prevent an accidental explosion of air,
the following instructions should be
observed:
The front fork with a built-in piston rod
has a very sophisticated internal con-
struction and is particularly sensitive to
foreign material.
Use enough care not to allow any foreign
material to come in when the oil is
replaced or when the front fork is disas-
sembled and reassembled.
Before removing the cap bolts or front
forks, be sure to extract the air from the
air chamber completely.
EC553000
REMOVAL POINTS
EC553150
Cap bolt
1. Remove:
Cap bolt 1
From the outer tube.
NOTE:
Before removing the front fork from the
machine, loosen the cap bolt.
2. Remove:
Cap bolt 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 remove the cap bolt.