2004 YAMAHA WR 450F warning

5 - 41
CHAS
EC5B3000
REMOVAL POINTS
EC5B3100
Master cylinder
1. Remove:
Master cylinder bracket 1
Master cylinder 2
CAUTION:
Do not let the master cylinder hang on the
brake hose.
Keep the master cylinder cap side hori-
zontal to prevent air from coming in.
EC5B3200
Grip
1. Remove:
Grip 1
NOTE:
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.
EC5B4000
INSPECTION
EC5B4100
Handlebar
1. Inspect:
Handlebar 1
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
HANDLEBAR

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CHASHANDLEBAR
4. Install:
Cover (grip cap) 1
Throttle grip 2
NOTE:
Apply the lithium soap base grease on the
throttle grip sliding surface.
5. Install:
Throttle cables 1
To tube guide 2.
NOTE:
Apply the lithium soap base grease on the
throttle cable end and tube guide cable wind-
ing portion.
6. Install:
Throttle cable cap 1
Screw (throttle cable cap) 2
WARNING
After tightening the screws, check that the
throttle grip 3 moves smoothly. If it does
not, retighten the bolts for adjustment.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
7. Install:
Cover (grip cap) 1
Cover (throttle cable cap) 2

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CHAS
EC560000
STEERING
Extent of removal:1 Under bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNINGSupport the machine securely so there is no
danger of it falling over.
Refer to “HANDLEBAR” section. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Headlight
Handlebar
Hose guide
Front fender
1 Coupler bracket 1
2 Trip meter 1
3 Main switch 1 Disconnect the main switch lead.
4 Steering shaft cap 1
5 Steering shaft nut 1
6 Front fork 2 Refer to “FRONT FORK” section.
7 Handle crown 1
8 Ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
9 Under bracket 1
10 Ball race cover 1
21
STEERING

5 - 48
CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
Ring nut 1
Use the ring nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Ring nut wrench:
YU-33975/90890-01403
EC563300
Bearing (lower)
1. Remove:
Bearing (lower) 1
Use the floor chisel 2.
CAUTION:
Take care not to damage the steering shaft
thread.
EC563400
Ball race
1. Remove:
Ball race 1
Remove the ball race using long rod 2
and the hammer.
EC564000
INSPECTION
EC564200
Steering shaft
1. Inspect:
Steering shaft 1
Bend/damage → Replace.
STEERING

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CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM REMOVAL
WARNINGSupport the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Brake hose holder
Rear caliper
Bolt (brake pedal)
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
Shift the brake pedal backward.
1 Chain support 1
2 Chain tensioner (lower) 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1

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CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:1 Rear shock absorber removal2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNINGSupport the machine securely so there is nodanger of it falling over.
Seat, fitting band and side covers Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
Air filter cover Refer to “AIR FILTER CLEANING” sec-
tion in the CHAPTER 3.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Coolant reservoir tank breather
hoseDisconnect at the coolant reservoir tank
side.
Coolant reservoir hose Disconnect at the coolant reservoir tank
side.
Battery Refer to “BATTERY INSPECTION AND
CHARGING” section in the CHAPTER 3.

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CHAS
EC586000
HANDLING NOTE
WARNING
This shock absorber is provided with a
separate type tank filled with high-pressure
nitrogen gas. To prevent the danger of
explosion, read and understand the follow-
ing information before handling the shock
absorber.
The manufacturer can not be held respon-
sible for property damage or personal
injury that may result from improper han-
dling.
1. Never tamper or attempt to disassem-
ble the cylinder or the tank.
2. Never throw the shock absorber into
an open flame or other high heat. The
shock absorber may explode as a
result of nitrogen gas expansion and/
or damage to the hose.
3. Be careful not to damage any part of
the gas tank. A damaged gas tank will
impair the damping performance or
cause a malfunction.
4. Take care not to scratch the contact
surface of the piston rod with the cylin-
der; or oil could leak out.
5. Never attempt to remove the plug at
the bottom of the nitrogen gas tank. It
is very dangerous to remove the plug.
6. When scrapping the shock absorber,
follow the instructions on disposal.
EC587000
NOTES ON DISPOSAL (YAMAHA DEALERS
ONLY)
Before disposing the shock absorber, be sure
to extract the nitrogen gas from valve 1. Wear
eye protection to prevent eye damage from
escaping gas and/or metal chips.
WARNING
To dispose of a damaged or worn-out
shock absorber, take the unit to your
Yamaha dealer for this disposal procedure.
REAR SHOCK ABSORBER

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–+ELECELECTRIC STARTING SYSTEM
EC624000
COUPLERS AND LEADS CONNECTION
INSPECTION
1. Check:
Couplers and leads connection
Rust/dust/looseness/short-circuit →
Repair or replace.
STARTER MOTOR OPERATION
1. Connect the positive battery terminal 1
and starter motor lead 2 with a jumper
lead 3.
Not operate → Repair or replace the
starter motor.
WARNING
A wire that is used as a jumper lead must
have at least the same capacity or more
as that of the battery lead, otherwise the
jumper lead may burn.
This check is likely to produce sparks,
therefore make sure nothing flammable is
in the vicinity.
STARTING CIRCUIT CUT-OFF RELAY
INSPECTION
1. Remove:
Starting circuit cut-off relay
2. Inspect:
Starting circuit cut-off relay conduct
Use 12 V battery.
Battery (+) lead → Blue/Black lead 1
Battery (–) lead → Brown lead 2
Tester (+) lead → Blue/White lead 3
Tester (–) lead → Black lead 4
L/W
3B
4
Tester selec-
tor position
Connected
to battery
Ω × 1Not
connected
to battery
2 4
3
1