2005 YAMAHA WR 450F oil

5 - 8
CHAS
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)
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.
FRONT WHEEL AND REAR WHEEL

5 - 24
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.
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
chemical reaction and lead to poor perfor-
mance.
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.
ÈFront
ÉRear
Recommended brake fluid:
DOT #4
T R..1 Nm (0.1 m · kg, 0.7 ft · lb)
È
É

5 - 27
CHASFRONT FORK
EC558000
FRONT FORK DISASSEMBLY
Extent of removal:
1 Oil seal removal
2 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 Oil seal 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 - 28
CHASFRONT FORK
EC556000
HANDLING NOTE
NOTE:
The front fork requires careful attention. So it is
recommended that the front fork be maintained
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.

5 - 29
CHAS
EC553201
Inner tube
1. Remove:
Dust seal 1
Stopper ring 2
Using slotted-head screwdriver.
CAUTION:
Take care not to scratch the inner tube.
2. Remove:
Inner tube 1
Oil seal removal steps:
Push in slowly a the inner tube just before
it bottoms out and then pull it back quickly
b.
Repeat this step until the inner tube can
be pulled out from the outer tube.
EC553311
Damper rod
1. Remove:
Base valve 1
Damper rod 2
NOTE:
Use a damper rod holder 3 to lock the damper
rod.
EC554000
INSPECTION
EC554100
Damper rod
1. Inspect:
Damper rod 1
Bend/damage → Replace damper rod.
CAUTION:
The front fork with a built-in piston rod has
a very sophisticated internal construction
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 disassembled and
reassembled.
Damper rod holder:
YM-1423/90890-01423
1
FRONT FORK

5 - 30
CHAS
EC554200
Base valve
1. Inspect:
Valve assembly 1
Wear/damage → Replace.
O-ring 2
Damage → Replace.
EC554400
Fork spring
1. Measure:
Fork spring free length a
Out of specification → Replace.
EC554502
Inner tube
1. Inspect:
Inner tube surface a
Score marks → Repair or replace.
Use #1,000 grit wet sandpaper.
Damaged oil lock piece → Replace.
Inner tube bends
Out of specification → Replace.
Use the dial gauge 1.
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken the
tube.
EC554600
Outer tube
1. Inspect:
Outer tube 1
Score marks/wear/damage → Replace.
Fork spring free length:
Standard Limit
460 mm (18.1 in) 455 mm (17.9 in)
Inner tube bending limit:
0.2 mm (0.008 in)
FRONT FORK

5 - 32
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
Oil seal 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.
Install the oil seal washer with its projections
b facing upward.
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 - 33
CHASFRONT FORK
9. Install:
Slide metal 1
Oil seal washer 2
To outer tube slot.
NOTE:
Press the slide metal into the outer tube with
fork seal driver 3.
Fork seal driver:
YM-01442/90890-01442
10. Install:
Oil seal 1
NOTE:
Press the oil seal into the outer tube with fork
seal driver 2.
Fork seal driver:
YM-01442/90890-01442
11. Install:
Stopper ring 1
NOTE:
Fit the stopper ring correctly in the groove in
the outer tube.
12. Install:
Dust seal 1
NOTE:
Apply the lithium soap base grease on the
inner tube.