2006 YAMAHA YZ450F wheel

5 - 6
CHASFRONT WHEEL AND REAR WHEEL
5. Install:
Wheel axle 1
NOTE:
Apply the lithium soap base grease on the
wheel axle.
6. Install:
Nut (wheel axle) 1
T R..105 Nm (10.5 m · kg, 75 ft · lb)
7. Tighten:
Bolt (axle holder) 1
NOTE:
Before tightening the bolt, fit the wheel axle to
the axle holder by stroking the front fork sev-
eral times with the front brake applied.
T R..23 Nm (2.3 m · kg, 17 ft · lb)

5 - 7
CHASFRONT WHEEL AND REAR WHEEL
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.
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..14 Nm (1.4 m · kg, 10 ft · lb)
T R..42 Nm (4.2 m · kg, 30 ft · lb)

5 - 8
CHAS
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.
FRONT WHEEL AND REAR WHEEL

5 - 9
CHASFRONT WHEEL AND REAR WHEEL
9. Adjust:
Drive chain slack a
Refer to “DRIVE CHAIN SLACK
ADJUSTMENT” section in the CHAPTER
3.
Drive chain slack:
48 ~ 58 mm (1.9 ~ 2.3 in)
10. Tighten:
Nut (wheel axle) 1
Locknut 2
T R..125 Nm (12.5 m · kg, 90 ft · lb)
T R..16 Nm (1.6 m · kg, 11 ft · lb)

5 - 11
CHAS
EC5A8100
REAR BRAKE
Extent of removal:
1 Master cylinder removal
2 Brake hose removal
3 Caliper removal
Extent of removal Order Part name Q’ty Remarks
REAR BRAKE REMOVAL
WARNING
Support 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.
Rear wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Drain the brake fluid. Refer to “REMOVAL POINTS”.
1 Brake pedal 1
2 Master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
7 Pad pin 1 Loosen when disassembling the caliper.
8 Caliper 1
3
1
321
FRONT BRAKE AND REAR BRAKE

5 - 19
CHASFRONT BRAKE AND REAR BRAKE
3. Install:
Caliper 1
Rear wheel 2
Refer to “FRONT WHEEL AND REAR
WHEEL” section.
4. Tighten:
Pad pin 3
5. Install:
Pad pin plug 4
Master cylinder kit
1. Clean:
Master cylinder
Master cylinder kit
Clean them with brake fluid.
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb)
2. Install:
Master cylinder cup (primary) 1
Master cylinder cup (secondary) 2
To master cylinder piston 3.
NOTE:
Apply the brake fluid on the master cylinder
cup.
WARNING
After installing, cylinder cup should be
installed as shown direction. Wrong instal-
lation cause improper brake performance.
ÈFront
ÉRear
ÈÉ
ÈÉ
3. Install:
Spring 1
To master cylinder piston 2.
NOTE:
Install the spring at the smaller dia. side.
ÈFront
ÉRear
ÈÉ

5 - 26
CHASFRONT FORK
EC550000
FRONT FORK
Extent of removal:
1 Front fork removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalFRONT FORK REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is no
danger of it falling over.
Front wheel Refer to “FRONT WHEEL AND REAR
WHEEL” section.
Front caliper Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Number plate Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
1 Protector 1
2 Pinch bolt (handle crown) 2 Only loosening.
3 Damper assembly 1 Loosen when disassembling the front
fork.
Use special tool.
Refer to “REMOVAL POINTS”.
4 Pinch bolt (under bracket) 2 Only loosening.
5 Front fork 1
1

7 - 16
TUN
EC72C001
Choosing set length
1. Place a stand or block under the engine to
put the rear wheel above the floor, and
measure the length a between the rear
wheel axle center and the rear fender hold-
ing bolt.
2. Remove the stand or block from the engine
and with a rider astride the seat, measure
the sunken length b between the rear
wheel axle center and the rear fender hold-
ing bolt.
3. Loosen the locknut 1 and make adjust-
ment by turning the spring adjuster 2 to
achieve the standard figure from the sub-
traction of the length b from the length a.
NOTE:
•If the machine is new and after it is broken in,
the same set length of the spring may
change because of the initial fatigue, etc. of
the spring. Therefore, be sure to make re-
evaluation.
•If the standard figure cannot be achieved by
adjusting the spring adjuster and changing
the spring set length, replace the spring with
an optional one and make re-adjustment.
Standard figure:
90 ~ 100 mm (3.5 ~ 3.9 in)
SETTING