2006 YAMAHA YZ450F brake

5 - 23
CHASFRONT BRAKE AND REAR BRAKE
4. Pass the brake hose through the cable
guide 1.
5. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the master
cylinder.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
Rear brake hose
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the caliper.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)

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..2 Nm (0.2 m · kg, 1.4 ft · lb)
È
É

5 - 25
CHASFRONT BRAKE AND REAR BRAKE
2. Air bleed:
Brake system
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section in the CHAPTER 3.
3. Inspect:
Brake fluid level
Fluid at lower level → Fill up.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section in the CHAPTER 3.
4. Install:
[Front]
Reservoir float
Diaphragm
Master cylinder cap 1
Screw (master cylinder cap) 2
[Rear]
Diaphragm
Master cylinder cap 1
Bolt (master cylinder cap) 2
CAUTION:
After installation, while pulling the lever in
or pushing down on the pedal, check
whether there is any brake fluid leaking
where the union bolts are installed respec-
tively at the master cylinder and caliper.
ÈFront
ÉRear
5. Install: (rear brake only)
Protector 1
Bolt (protector) 2
È
É
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

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

5 - 44
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.
EC5B5000
ASSEMBLY AND INSTALLATION
Handlebar
1. Install:
Handlebar holder (lower) 1
Plain washer 2
Nut [handlebar holder (lower)] 3
NOTE:
Install the handlebar holder (lower) with its
side having the greater distance a from the
mounting bolt center facing forward.
Apply the lithium soap base grease on the
thread of the handlebar holder (lower).
Installing the handlebar holder (lower) in the
reverse direction allows the front-to-rear off-
set amount of the handlebar position to be
changed.
Do not tighten the nut yet.
HANDLEBAR

5 - 54
CHASSWINGARM
EC570000
SWINGARM
Extent of removal:
1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM 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.
Brake hose holder
Refer to “FRONT BRAKE AND REAR
BRAKE” section.
Rear caliper
Bolt (brake pedal) Shift the brake pedal backward.
Drive chain
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