2005 YAMAHA WR 450F steering

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INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
Bearing free play
Exist play → Replace.
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
Steering shaft
Grasp the bottom of the forks and gently
rock the fork assembly back and forth.
Free play → Adjust steering head.
3. Check:
Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action → Adjust steering ring
nut.
4. Adjust:
Steering ring nut
Steering ring nut adjustment steps:
Remove the headlight.
Remove the handlebar and handle crown.
Loosen the ring nut 1 using the ring nut
wrench 2.
Ring nut wrench:
YU-33975/90890-01403

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INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
Tighten the ring nut 3 using ring nut
wrench 4.
NOTE:
Set the torque wrench to the ring nut wrench
so that they form a right angle.
Ring nut wrench:
YU-33975/90890-01403
T R..
Ring nut (initial tightening):
38 Nm (3.8 m  kg, 27 ft  lb)
Loosen the ring nut one turn.
Retighten the ring nut using the ring nut
wrench.
WARNING
Avoid over-tightening.
T R..
Ring nut (final tightening):
7 Nm (0.7 m  kg, 5.1 ft  lb)
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.
Install the plain washer 5, handle crown
6, plain washer 7, steering shaft nut 8,
steering shaft cap 9, handlebar 0, han-
dlebar holder A and headlight B.
NOTE:
The handlebar holder should be installed
with the punched mark a forward.
Install the handlebar so that the marks b
are in place on both sides.
Insert the end of the fuel breather hose C
into the hole in the steering shaft cap.
CAUTION:
First tighten the bolts on the front side of
the handlebar holder, and then tighten
the bolts on the rear side.

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INSP
ADJ
T R..
Steering shaft nut:
145 Nm (14.5 m  kg, 105 ft  lb)
Handlebar holder:
28 Nm (2.8 m  kg, 20 ft  lb)
Pinch bolt (handle crown):
23 Nm (2.3 m  kg, 17 ft  lb)
Headlight (left and right):
7 Nm (0.7 m  kg, 5.1 ft  lb)
Headlight (lower):
7 Nm (0.7 m  kg, 5.1 ft  lb)
STEERING HEAD INSPECTION AND ADJUSTMENT

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CHAS
13. Insert the end of the fuel breather hose 1
into the hole in the steering shaft cap 2.
2
1
HANDLEBAR

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CHAS
EC560000
STEERING
Extent of removal:
1 Under bracket removal
2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is nodanger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Headlight
Handlebar Refer to “HANDLEBAR” section.
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 Bearing race cover 1
21
STEERING

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CHASSTEERING
Extent of removal Order Part name Q’ty Remarks
11 Bearing (upper) 1
12 Bearing (lower) 1
Refer to “REMOVAL POINTS”.
13 Bearing race 2
2

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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.
Bearing race
1. Remove:
Bearing race 1
Remove the bearing 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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CHASSTEERING
Bearing and bearing race
1. Wash the bearings and bearing races with
a solvent.
2. Inspect:
Bearing 1
Bearing race
Pitting/damage → Replace bearings and
bearing races as a set.
Install the bearing in the bearing races.
Spin the bearings by hand. If the bearings
hang up or are not smooth in their opera-
tion in the bearing races, replace bear-
ings and bearing races as a set.
EC565000
ASSEMBLY AND INSTALLATION
Under bracket
1. Install:
Bearing (lower) 1
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
Bearing race
Bearing (upper) 1
Bearing race cover 2
NOTE:
Apply the lithium soap base grease on the
bearing and bearing race cover lip.
3. Install:
Under bracket 1
NOTE:
Apply the lithium soap base grease on the
bearing and the portion a of the steering
shaft.