2008 YAMAHA YZ450F lock

5-14
FRONT BRAKE AND REAR BRAKE
4. Install:
• Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake master cylinder.
INSTALLING THE REAR BRAKE
HOSE
1. Install:
• Copper washer "1"
• Brake hose "2"
• Union bolt "3"
Always use new copper washers.
Install the brake hose so that its
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake caliper.
2. Install:
• Brake hose holder "1"
• Screw (brake hose holder) "2"
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.
FILLING THE BRAKE FLUID
1. Fill:
•Brake fluid
Until the fluid level reaches
"LOWER" level line "a".
• Use only the designated quality
brake fluid:
otherwise, the rubber seals may
deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake
fluid;
mixing fluids may result in a
harmful chemical reaction and
lead to poor performance.
• Be careful that water does not
enter the master cylinder when
refilling. Water will significantly lower the boiling point of the flu-
id and may result in vapor lock.
Brake fluid may erode painted sur-
faces or plastic parts. Always
clean up spilled fluid immediately.
A. Front
B. Rear
2. Air bleed:
• Brake system
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
tion in the CHAPTER 3.
3. Inspect:
• Brake fluid level
Fluid at lower level
→Fill up.
Refer to "CHECKING THE
BRAKE FLUID LEVEL" section in
the CHAPTER 3.
4. Install:
• Reservoir float (front brake)
• Diaphragm
• Brake master cylinder cap "1"
• Screw (brake master cylinder
cap) "2"
After installation, while pulling the
brake lever in or pushing down on
the brake pedal, check whether
there is any brake fluid leaking
where the union bolts are installed
respectively at the brake master
cylinder and brake caliper.
Union bolt:
30 Nm (3.0 m•kg, 22
ft•lb)
Union bolt:
30 Nm (3.0 m•kg, 22
ft•lb)
Screw (brake hose hold-
er):
2 Nm (0.2 m•kg, 1.4
ft•lb)
Recommended brake flu-
id:
DOT #4
Screw (bolt) {brake mas-
ter cylinder cap}:
2 Nm (0.2 m•kg, 1.4
ft•lb)

5-18
FRONT FORK
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
The front fork requires careful atten-
tion. So it is recommended that the
front fork be maintained at the deal-
ers.
To prevent an accidental explosion
of air, the following instructions
should be observed:
• The front fork with a built-in pis-
ton rod has a very sophisticated
internal construction and is par-
ticularly sensitive to foreign ma-
terial. 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 base valves
or front forks, be sure to extract
the air from the air chamber com-
pletely.
REMOVING THE DAMPER
ASSEMBLY
1. Loosen:
• Damper assembly "1"
Before removing the front fork from
the machine, loosen the damper as-
sembly with the cap bolt ring wrench
"2".
REMOVING THE ADJUSTER
1. Drain the outer tube of its front
fork oil at its top.
2. Loosen:
•Adjuster "1"3. Remove:
•Adjuster "1"
• While compressing the inner tube
"2", set the cap bolt ring wrench "4"
between the inner tube and locknut
"3".
• Hold the locknut and remove the
adjuster.
Do not remove the locknut as the
damper rod may go into the damp-
er assembly and not be taken out.
REMOVING THE INNER TUBE
1. Remove:
• Dust seal "1"
• Stopper ring "2"
Using slotted-head screwdriver.
Take care not to scratch the inner
tube.
2. Remove:
• Inner tube "1"
Oil seal removal steps:
a. Push in slowly "a" the inner tube
just before it bottoms out and then
pull it back quickly "b".
b. Repeat this step until the inner
tube can be pulled out from the
outer tube.
REMOVING THE BASE VALVE
1. Remove:
• Base valve "1"
From damper assembly "2".
Hold the damper assembly with the
cap bolt ring wrench "3" and use the
cap bolt wrench "4" to remove the
base valve.
CHECKING THE DAMPER
ASSEMBLY
1. Inspect:
• Damper assembly "1"
Bend/damage
→ Replace.
• O-ring "2"
Wear/damage
→ Replace.
The front fork with a built-in piston
rod has a very sophisticated inter-
nal 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 re-
assembled.
CHECKING THE BASE VALVE
1. Inspect:
• Base valve "1"
Wear/damage
→Replace. Cap bolt ring wrench:
YM-01501/90890-01501
Cap bolt ring wrench:
YM-01501/90890-01501
Cap bolt wrench:
YM-01500/90890-01500
Cap bolt ring wrench:
YM-01501/90890-01501

5-19
FRONT FORK
Contamination →Clean.
• O-ring "2"
Wear/damage
→Replace.
• Piston metal "3"
Wear/damage
→Replace.
• Spring "4"
Damage/fatigue
→Replace base
valve.
• Air bleed screw "5"
Wear/damage
→Replace.
CHECKING THE COLLAR
1. Inspect:
• Piston metal "1"
Wear/damage
→Replace.
CHECKING THE FORK SPRING
1. Measure:
• Fork spring free length "a"
Out of specification
→Replace.
CHECKING THE INNER TUBE
1. Inspect:
• Inner tube surface "a"
Score marks
→Repair or replace.
Use #1,000 grit wet sandpaper.
Damaged oil lock piece
→Re-
place.
• Inner tube bends
Out of specification
→Replace.
Use the dial gauge "1".
The bending value is shown by one half of the dial gauge reading.
Do not attempt to straighten a bent
inner tube as this may dangerous-
ly weaken the tube.
CHECKING THE OUTER TUBE
1. Inspect:
• Outer tube "1"
Score marks/wear/damage
→Re-
place.
CHECKING THE ADJUSTER
1. Inspect:
•Adjuster "1"
• O-ring "2"
Wear/damage
→Replace.
ASSEMBLING THE FRONT FORK
1. Wash the all parts in a clean sol-
vent.
2. Stretch the damper assembly ful-
ly.
3. Fill:
• Front fork oil "1"
To damper assembly.
• Be sure to use recommended
fork oil. If other oils are used,
they may have an excessively ad-
verse effect on the front fork per-
formance.
• Never allow foreign materials to enter the front fork.
4. After filling, pump the damper as-
sembly "1" slowly up and down
(about 200 mm (7.9 in) stroke)
several times to bleed the damper
assembly of air.
Be careful not to excessive full stroke.
A stroke of 200 mm (7.9 in) or more
will cause air to enter. In this case, re-
peat the steps 2 to 4.
5. Measure:
• Oil level (left and right) "a"
Out of specification
→ Adjust.
6. Tighten:
• Locknut "1"
Fully finger tighten the locknut onto
the damper assembly.
Fork spring free length:
454 mm (17.9 in)
: 449 mm (17.7
in)
Inner tube bending limit:
0.2 mm (0.008 in)
Recommended oil:
Suspension oil "S1"
Oil capacity:
199 cm
3 (7.00 Imp oz,
6.73 US oz)
Standard oil level:
145-148 mm (5.71-5.83
in)
From top of fully
stretched damper as-
sembly.

5-21
FRONT FORK
tube with fork seal driver "3".
19. Install:
• Oil seal "1"
Press the oil seal into the outer tube
with fork seal driver "2".
20. Install:
• Stopper ring "1"
Fit the stopper ring correctly in the
groove in the outer tube.
21. Install:
• Dust seal "1"
Apply the lithium soap base grease
on the inner tube.
22. Check:
• Inner tube smooth movement
Tightness/binding/rough spots

→
Repeat the steps 15 to 21.
23. Measure:
• Distance "a"
Out of specification
→ Turn into
the locknut.
24. Install:
• Collar "1"
• Fork spring "2"
To damper assembly "3".
Install the collar with its larger dia.
end "a" facing the fork spring.
25. Install:
• Damper assembly "1"
To inner tube "2".
To install the damper assembly
into the inner tube, hold the inner
tube aslant. If the inner tube is held vertically, the damper assembly
may fall into it, damaging the valve
inside.
26. Loosen:
• Rebound damping adjuster "1"
• Loosen the rebound damping ad-
juster finger tight.
• Record the set position of the ad-
juster (the amount of turning out the
fully turned in position).
27. Install:
• Push rod "1"
• Copper washer "2"
•Adjuster "3"
To damper assembly "4".
• While compressing the inner tube
"5", set the cap bolt ring wrench "7"
between the inner tube and locknut
"6".
• Fully finger tighten the adjuster onto
the damper assembly.
28. Inspect:
• Gap "a" between the adjuster "1"
and locknut "2".
Out of specification
→ Retighten
and readjust the locknut. Fork seal driver:
YM-A0948/90890-01502
Fork seal driver:
YM-A0948/90890-01502
Distance "a":
16 mm (0.63 in) or more
Between the damper
assembly "1" bottom
and locknut "2" bot-
tom.
Cap bolt ring wrench:
YM-01501/90890-01501
Gap "a" between the ad-
juster and locknut:
0.5–1.0 mm (0.02–0.04
in)

5-22
FRONT FORK
If the adjuster is installed out of spec-
ification, proper damping force can-
not be obtained.
29. Tighten:
• Adjuster (locknut) "1"
Hold the locknut "2" and tighten the
adjuster with specified torque.
30. Install:
• Adjuster "1"
To inner tube.
31. Fill:
• Front fork oil "1"
From outer tube top.
Never fail to make the oil amount
adjustment between the maximum
and minimum amount and always adjust each front fork to the same
setting. Uneven adjustment can
cause poor handling and loss of
stability.
• Be sure to use recommended
fork oil. If other oils are used,
they may have an excessively ad-
verse effect on the front fork per-
formance.
• Never allow foreign materials to
enter the front fork.
32. Install:
• Damper assembly "1"
To outer tube.
Temporarily tighten the damper as-
sembly.
33. Install:
• Protector guide "1"
INSTALLING THE FRONT FORK
1. Install:
• Front fork "1"
• Temporarily tighten the pinch bolts
(lower bracket).
• Do not tighten the pinch bolts (up-
per bracket) yet.
2. Tighten:
• Damper assembly "1"
Use the cap bolt ring wrench "2" to
tighten the damper assembly with
specified torque.
3. Adjust:
• Front fork top end "a"
4. Tighten:
• Pinch bolt (upper bracket) "1"
• Pinch bolt (lower bracket) "2"
Tighten the lower bracket to speci-
fied torque. If torqued too much, it
may cause the front fork to mal-
function.
Adjuster (locknut):
29 Nm (2.9 m•kg, 21
ft•lb)
Adjuster:
55 Nm (5.5 m•kg, 40
ft•lb)
Recommended oil:
Suspension oil "S1"
Standard oil amount:
350 cm
3 (12.3 Imp oz,
11.8 US oz)
Extent of adjustment:
300–375 cm
3
(10.6–13.2 Imp oz,10.1–
12.7 US oz)
Damper assembly:
30 Nm (3.0 m•kg, 22
ft•lb)
Cap bolt ring wrench:
YM-01501/90890-01501
Front fork top end (stan-
dard) "a":
5 mm (0.20 in)
Pinch bolt (upper brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
Pinch bolt (lower brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)

5-30
STEERING
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE STEERING RING
NUT
1. Remove:
• Steering ring nut "1"
Use the steering nut wrench "2".
Support the steering stem so that
it may not fall down.
REMOVING THE LOWER
BEARING
1. Remove:
• Lower bearing "1"
Use the floor chisel "2".
Take care not to damage the steer-
ing shaft thread.
REMOVING THE BEARING RACE
1. Remove:
• Bearing race "1"
Remove the bearing race using
long rod "2" and the hammer.
CHECKING THE STEERING STEM
1. Inspect:
• Steering stem "1"
Bend/damage
→Replace.CHECKING THE BEARING AND
BEARING RACE
1. Wash the bearings and bearing
races with a solvent.
2. Inspect:
•Bearing "1"
• Bearing race
Pitting/damage
→Replace bear-
ings 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 operation in the
bearing races, replace bearings
and bearing races as a set.
INSTALLING THE LOWER
BRACKET
1. Install:
• Lower bearing "1"
Apply the lithium soap base grease
on the dust seal lip and bearing inner
circumference.
2. Install:
• Bearing race
• Upper bearing "1"
• Bearing race cover "2"
Apply the lithium soap base grease
on the bearing and bearing race cov-
er lip.
3. Install:
• Lower bracket "1"
Apply the lithium soap base grease
on the bearing, the portion "a" and
thread of the steering stem.
4. Install:
• Steering ring nut "1"
Tighten the steering ring nut using
the steering nut wrench "2".
Refer to "CHECKING AND AD-
JUSTING THE STEERING
HEAD" section in the CHAPTER
3.
5. Check the steering stem by turn-
ing it lock to lock. If there is any
binding, remove the steering stem
assembly and inspect the steer-
ing bearings. Steering nut wrench:
YU-33975/90890-01403
Steering ring nut:
7 Nm (0.7 m•kg, 5.1 ft•
lb)

5-37
REAR SHOCK ABSORBER
REAR SHOCK ABSORBER
REMOVING THE REAR SHOCK ABSORBER
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the engine.Refer to "HANDLING NOTE".
Seat Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section in the CHAPTER 4.
Silencer Refer to "EXHAUST PIPE AND SILENCER"
section in the CHAPTER 4.
1 Clamp (air filter joint) 1 Only loosening.
2Rear frame 1
3 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
4 Bolt (rear shock absorber-frame) 1
5 Rear shock absorber 1
6 Locknut 1 Only loosening.
7 Adjuster 1 Only loosening.
8 Spring seat 2
9 Lower spring guide 1
10 Upper spring guide 1
11 Spring (rear shock absorber) 1

5-40
REAR SHOCK ABSORBER
3. Install:
• Lower bearing "1"
Install the bearing by pressing it on
the side having the manufacture's
marks or numbers.
INSTALLING THE SPRING (REAR
SHOCK ABSORBER)
1. Install:
• Spring "1"
• Upper spring guide "2"
• Lower spring guide "3"
2. Install:
• Spring seat "1"
Install the spring seat with the projec-
tion "a" brought into contact with the
spring end, as shown.
3. Tighten:
•Adjuster "1"
4. Adjust:
• Spring length (installed)
Refer to "ADJUSTING THE
REAR SHOCK ABSORBER
SPRING PRELOAD" section in
the CHAPTER 3.
5. Tighten:
• Locknut "1"
INSTALLING THE REAR SHOCK
ABSORBER
1. Install:
• Dust seal "1"
• O-ring "2"
• Collar "3"
• Apply the molybdenum disulfide
grease on the dust seal lips and col-
lars.
• Apply the lithium soap base grease
on the O-rings.
2. Install:
• Bushing "1"
• Collar "2"
• Dust seal "3"
• Apply the molybdenum disulfide
grease on the bearing and dust seal
lips.
• Install the dust seals with their lips
facing outward.
3. Install:
• Rear shock absorber
4. Install:
• Bolt (rear shock absorber-frame)
"1"
• Washer "2"
• Nut (rear shock absorber-frame)
"3"
Apply the molybdenum disulfide
grease on the bolt.
5. Install:
• Bolt (rear shock absorber-relay
arm) "1"
• Nut (rear shock absorber-relay
arm) "2"
Apply the molybdenum disulfide
grease on the bolt.
6. Install:
• Rear frame "1"
• Bolt [rear frame (upper)] "2" Installed depth of the
bearing "a":
4 mm (0.16 in)
Nut (rear shock absorb-
er-frame):
56 Nm (5.6 m•kg, 40
ft•lb)
Nut (rear shock absorb-
er-relay arm):
53 Nm (5.3 m•kg, 38
ft•lb)
Bolt [rear frame (upper)]:
38 Nm (3.8 m•kg, 27
ft•lb)