2009 YAMAHA WR 450F lock

3-20
CHASSIS
2. Remove:
• Brake lever cover
3. Adjust:
• Brake lever position
Brake lever position adjustment
steps:
a. Loosen the locknut "1".
b. Turn the adjusting bolt "2" until the
lever position "a" is within speci-
fied position.
c. Tighten the locknut.
Be sure to tighten the locknut, as it
will cause poor brake perfor-
mance.
4. Install:
• Brake lever cover
ADJUSTING THE REAR BRAKE
1. Check:
• Brake pedal height "a"
Out of specification→Adjust.
2. Adjust:
• Brake pedal height
Pedal height adjustment steps:
a. Loosen the locknut "1".
b. Turn the adjusting nut "2" until the
pedal height "a" is within specified
height.
c. Tighten the locknut.
• Adjust the pedal height between
the maximum "A" and the mini-
mum "B" as shown. (In this ad-
justment, the bolt "3" end "b"
should protrude out of the
threaded portion "4" but not be
less than 2 mm (0.08 in) "c" away
from the brake pedal "5").
• After the pedal height adjust-
ment, make sure that the rear
brake does not drag.
CHECKING AND REPLACING THE
FRONT BRAKE PADS
1. Inspect:
• Brake pad thickness "a"
Out of specification→Replace as
a set.
2. Replace:
•Brake pad
Brake pad replacement steps:
a. Remove the pad pin plug "1".b. Loosen the pad pin "2".
c. Remove the brake caliper "3"
from the front fork.
d. Remove the pad pin and brake
pads "4".
e. Connect the transparent hose "5"
to the bleed screw "6" and place
the suitable container under its
end.
f. Loosen the bleed screw and push
the brake caliper piston in.
Do not reuse the drained brake flu-
id.
g. Tighten the bleed screw.
h. Install the brake pads "7" and pad
pin.
• Install the brake pads with their pro-
jections "a" into the brake caliper re-
cesses "b".
• Temporarily tighten the pad pin at
this point.
Locknut:
5 Nm (0.5 m •kg, 3.6
ft•lb)
Brake pedal height "a":
10 mm (0.39 in)
Brake pad thickness:
4.4 mm (0.17 in)
: 1.0 mm (0.04
in)
Bleed screw:
6 Nm (0.6 m•kg, 4.3
ft•lb)

3-23
CHASSIS
6. Install:
• Chain joint "1"
• O-ring "2"
• Drive chain "3"
• Link plate "4"
When installing the drive chain, apply
the lithium soap base grease on the
chain joint and O-rings.
7. Install:
• Link plate
• Press the link plate onto the chain
joint using a drive chain riveter "5".
• Rivet the end of the chain joint us-
ing a drive chain riveter.
• After riveting the chain joint, make
sure its movement is smooth.
8. Lubricate:
• Drive chain
ADJUSTING THE DRIVE CHAIN
SLACK
1. Elevate the rear wheel by placing
the suitable stand under the en-
gine.
2. Check:
• Drive chain slack "a"
Above the seal guard installation
bolt.Out of specification→Adjust.
Before checking and/or adjusting, ro-
tate the rear wheel through several
revolutions and check the slack sev-
eral times to find the tightest point.
Check and/or adjust the drive chain
slack with the rear wheel in this "tight
chain" position.
3. Adjust:
• Drive chain slack
Drive chain slack adjustment
steps:
a. Loosen the axle nut "1" and lock-
nuts "2".
b. Adjust the drive chain slack by
turning the adjusters "3".
c. Turn each adjuster exactly the
same amount to maintain correct
axle alignment. (There are marks
"a" on each side of the drive chain
puller alignment.) NOTICE: Im-
proper drive chain slack will
overload the engine as well as
other vital parts of the motorcy-
cle and can lead to chain slip-
page or breakage. To prevent
this from occurring, keep the
drive chain slack within the
specified limits.
Turn the adjuster so that the drive
chain is in line with the sprocket, as
viewed from the rear.
d. Tighten the axle nut while pushing
down the drive chain.
e. Tighten the locknuts.
CHECKING THE FRONT FORK
1. Inspect:
• Front fork smooth action
Operate the front brake and
stroke the front fork.
Unsmooth action/oil leakage→
Repair or replace.
CLEANING THE FRONT FORK OIL
SEAL AND DUST SEAL
1. Remove:
•Protector
• Dust seal "1"
Use a thin screw driver, and be care-
ful not to damage the inner fork tube
and dust seal.
2. Clean:
• Dust seal "a"
• Oil seal "b"
• Clean the dust seal and oil seal af-
ter every run.
• Apply the lithium soap base grease
on the inner tube.
Drive chain lubricant:
SAE 10W-30 motor oil
or suitable chain lubri-
cants
Drive chain slack:
48–58 mm (1.9–2.3 in)
To tighten→Turn the adjuster "3"
counterclockwise.
To loosen→Turn the adjuster "3"
clockwise and push wheel for-
ward.
Axle nut:
125 Nm (12.5 m•kg, 90
ft•lb)
Locknut:
19 Nm (1.9 m•kg, 13
ft•lb)

3-25
CHASSIS
4. Adjust:
• Spring preload
Adjustment steps:
a. Loosen the locknut "1".
b. Loosen the adjuster "2" until there
is some clearance between the
spring and adjuster.
c. Measure the spring free length
"a".
d. Turn the adjuster "2".
• Be sure to remove all dirt and mud
from around the locknut and adjust-
er before adjustment.
• The length of the spring (installed)
changes 1.5 mm (0.06 in) per turn
of the adjuster.
Never attempt to turn the adjuster
beyond the maximum or minimum
setting.
e. Tighten the locknut.
5. Install:
• Rear frame (upper)• Rear frame (lower)
ADJUSTING THE REAR SHOCK
ABSORBER REBOUND DAMPING
FORCE
1. Adjust:
• Rebound damping force
By turning the adjuster "1".
• STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the bracket.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
ADJUSTING THE REAR SHOCK
ABSORBER LOW COMPRESSION
DAMPING FORCE
1. Adjust:
• Low compression damping force
By turning the adjuster "1".
• STANDARD POSITION:
This is the position which is back
by the specific number of clicks
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the high compression
damping adjuster.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Stiffer →Increase the spring pre-
load. (Turn the adjuster "2" in.)
Softer→Decrease the spring pre-
load. (Turn the adjuster "2"
out.)
Extent of adjustment:
Maximum Minimum
Position in
which the
spring is turned
in 13 mm (0.51
in) from its free
length.Position in
which the
spring is turned
in 1.5 mm (0.06
in) from its free
length.
Locknut:
30 Nm (3.0 m•kg, 22
ft•lb)
Rear frame (upper):
38 Nm (3.8 m•kg, 27
ft•lb)
Rear frame (lower):
32 Nm (3.2 m•kg, 23
ft•lb)
Stiffer "a" →Increase the re-
bound damping force. (Turn
the adjuster "1" in.)
Softer "b" →Decrease the re-
bound damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)
Standard position:
About 11 clicks out
Stiffer "a" →Increase the low
compression damping force.
(Turn the adjuster "1" in.)
Softer "b" →Decrease the low
compression damping force.
(Turn the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)
Standard position:
About 8 clicks out
* About 9 clicks out
** About 11 clicks out
* For AUS, NZ and ZA
** For EUROPE

3-26
CHASSIS
ADJUSTING THE REAR SHOCK
ABSORBER HIGH COMPRESSION
DAMPING FORCE
1. Adjust:
• High compression damping force
By turning the adjuster "1".
• STANDARD POSITION:
This is the position which is back
by the specific number of turns
from the fully turned-in position.
(Which align the punch mark "a"
on the adjuster with the punch
mark "b" on the adjuster body.)
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
CHECKING THE TIRE PRESSURE
1. Measure:
• Tire pressure
Out of specification→Adjust.
• Check the tire while it is cold.
• Loose bead stoppers allow the tire
to slip off its position on the rim
when the tire pressure is low.
• A tilted tire valve stem indicates that
the tire slips off its position on the
rim.
• If the tire valve stem is found tilted,
the tire is considered to be slipping
off its position. Correct the tire posi-
tion.
CHECKING AND TIGHTENING THE
SPOKES
The following procedure applies to all
of the spokes.
1. Check:
• Spokes
Bend/damage→Replace.
Loose spoke→Retighten.
Tap the spokes with a screwdriv-
er.
A tight spoke will emit a clear, ringing
tone; a loose spoke will sound flat.
2. Tighten:
• Spokes
(with a spoke nipple wrench "1")
Be sure to retighten these spokes be-
fore and after break-in.
CHECKING THE WHEELS
1. Inspect:
• Wheel runout
Elevate the wheel and turn it.
Abnormal runout→ Replace.
2. Inspect:
• Bearing free play
Exist play→Replace.
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Place a stand under the engine to
raise the front wheel off the
ground. WARNING! Securely
support the vehicle so that
there is no danger of it falling
over.
2. Check:
• Steering stem
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 steer-
ing ring nut. Stiffer "a" →Increase the high
compression damping force.
(Turn the adjuster "1" in.)
Softer "b" →Decrease the high
compression damping force.
(Turn the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position2 turns out
(from maximum
position)
Standard position:
About 1-1/8 turns out
* About 1-1/4 turns out
* For AUS, NZ and ZA
Standard tire pressure:
100 kPa (1.0 kgf/cm
2,
15 psi)
Spoke nipple wrench:
YM-01521/90980-01521
Spokes:
3 Nm (0.3 m•kg, 2.2
ft•lb)

3-27
CHASSIS
4. Adjust:
• Steering ring nut
Steering ring nut adjustment
steps:
a. Remove the headlight.
b. Remove the handlebar and upper
bracket.
c. Loosen the steering ring nut "1"
using the steering nut wrench "2".
d. Tighten the steering ring nut "3"
using steering nut wrench "4".
• Apply the lithium soap base grease
on the thread of the steering stem.
• Set the torque wrench to the steer-
ing nut wrench so that they form a
right angle.
e. Loosen the steering ring nut one
turn.
f. Retighten the steering ring nut us-
ing the steering nut wrench.
Avoid over-tightening.
g. 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.
h. Install the washer "5", upper
bracket "6", washer "7", steering
stem nut "8", handlebar "9", han-
dlebar upper holder "10" and
headlight "11".
• The handlebar upper holder should
be installed with the punched mark
"a" forward.
• Install the handlebar so that the
marks "b" are in place on both
sides.
• Install the handlebar so that the pro-
jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• Insert the end of the fuel breather
hose "12" into the hole in the steer-
ing stem.
First tighten the bolts on the front
side of the handlebar upper holder,
and then tighten the bolts on the
rear side.
Steering nut wrench:
YU-33975/90890-01403
Steering nut wrench:
YU-33975/90890-01403
Steering ring nut (initial
tightening):
38 Nm (3.8 m•kg, 27
ft•lb)
Steering ring nut (final
tightening):
7 Nm (0.7 m•kg, 5.1
ft•lb)
Steering stem nut:
145 Nm (14.5 m•kg, 105
ft•lb)
Handlebar upper holder:
28 Nm (2.8 m•kg, 20
ft•lb)
Pinch bolt (upper brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
Headlight:
7 Nm (0.7 m•kg, 5.1
ft•lb)

3-33
ELECTRICAL
6. Install:
•Battery
• Battery band
7. Connect:
• Battery leads
(to the battery terminals)
First, connect the positive lead "1",
then the negative lead "2".
8. Check:
• Battery terminals
Dirt→Clean with a wire brush.
Loose connection→Connect
properly.
9. Lubricate:
• Battery terminal
10. Install:
• Seat
CHECKING THE FUSE
To avoid a short circuit, always set
the main switch to "OFF" when
checking or replacing a fuse.
1. Remove:
• Seat
• Fuse cover
2. Check:
• Continuity
Checking steps:
a. Remove the fuse "1".
b. Connect the pocket tester to the
fuse and check the continuity.
Set the pocket tester selector to " Ω×
1".
2. Reserve fuse
c. If the pocket tester indicates "∞",
replace the fuse.
3. Replace:
• Blown fuse
Replacement steps:
a. Set the main switch to "OFF".
b. Install a new fuse of the correct
amperage.
c. Set on the switches to verify if the
electrical circuit is operational.
d. If the fuse immediately blows
again, check the electrical circuit.
Never use a fuse with an amperage
rating other than that specified. Im-
provising or using a fuse with the
wrong amperage rating may cause
extensive damage to the electrical
system, cause the starting and ig-
nition systems to malfunction and
could possibly cause a fire.
4. Install:
• Fuse cover
•Seat
REPLACING THE HEADLIGHT
BULBS
1. Remove:
• Headlight
Refer to "REMOVING THE SEAT,
FUEL TANK AND SIDE COV-
ERS" section.2. Remove:
• Headlight bulb holder cover "1"
3. Remove:
• Headlight bulb holder "1"
Remove the headlight bulb holder by
pushing it in and turning it counter-
clockwise.
4. Remove:
• Headlight bulb
Since the headlight bulb gets ex-
tremely hot, keep flammable prod-
ucts and your hands away from the
bulb unit it has cooled down.
5. Install:
• Headlight bulb
Avoid touching the glass part of
the headlight bulb to keep it free
form oil, otherwise the transparen-
cy of the glass, the life of the bulb
and the luminous flux will be ad-
versely affected. If the headlight
bulb gets soiled, thoroughly clean
it with a cloth moistened with alco-
hol or lacquer thinner.
6. Install:
• Headlight bulb holder
7. Install:
• Headlight bulb holder cover
8. Install:
• Headlight
Refer to "REMOVING THE SEAT,
FUEL TANK AND SIDE COV-
ERS" section. Recommended lubricant:
Lithium soap base
grease
Pocket tester:
YU-3112-C/90890-
03112
Items Amperage
ratingQ'ty
Main fuse 10 A 1
Headlight:
7 Nm (0.7 m•kg, 5.1
ft•lb)

4-5
CHASSIS
CHASSIS
SELECTION OF THE SECONDARY
REDUCTION RATIO (SPROCKET)
ondary gear reduction ratio>
• It is generally said that the second-
ary gear ratio should be reduced for
a longer straight portion of a speed
course and should be increased for
a course with many corners. Actual-
ly, however, as the speed depends
on the ground condition of the day
of the ride, be sure to run through
the circuit to set the machine suit-
able for the entire course.
• In actuality, it is very difficult to
achieve settings suitable for the en-
tire course and some settings may
be sacrificed. Thus, the settings
should be matched to the portion of
the course that has the greatest ef-
fect on the ride result. In such a
case, run through the entire course
while making notes of lap times to
find the best balance; then, deter-
mine the secondary reduction ratio.
• If a course has a long straight por-
tion where a machine can run at
maximum speed, the machine is
generally set such that it can devel-
op its maximum revolutions toward
the end of the straight line, with care
taken to avoid the engine over-rev-
ving.
Riding technique varies from rider to
rider and the performance of a ma-
chine also vary from machine to ma-
chine. Therefore, do not imitate other
rider's settings from the beginning but
choose your own setting according to
the level of your riding technique.
DRIVE AND REAR WHEEL
SPROCKETS SETTING PARTSTIRE PRESSURE
Tire pressure should be adjust to suit
the road surface condition of the cir-
cuit.
• Under a rainy, muddy, sandy, or
slippery condition, the tire pressure
should be lower for a larger area of
contact with the road surface.
• Under a stony or hard road condi-
tion, the tire pressure should be
higher to prevent a flat tire.
FRONT FORK SETTING
The front fork setting should be made
depending on the rider's feeling of an
actual run and the circuit conditions.
The front fork setting includes the fol-
lowing three factors:
1. Setting of air spring characteris-
tics
• Change the fork oil level.
2. Setting of spring preload
• Change the spring.
• Install the adjustment washer.
3. Setting of damping force
• Change the compression damp-
ing.
• Change the rebound damping.
The spring acts on the load and
the damping force acts on the
cushion travel speed.
CHANGE IN LEVEL AND
CHARACTERISTICS OF FORK OIL
Damping characteristic near the final
stroke can be changed by changing
the fork oil amount.
Adjust the oil level in 5 mm (0.2 in)
increments or decrements. Too
low oil level causes the front fork
to produce a noise at full rebound
or the rider to feel some pressure
on his hands or body. Alternative-
ly, too high oil level will develop
unexpectedly early oil lock with
the consequent shorter front fork
travel and deteriorated perfor-
mance and characteristics. There-
fore, adjust the front fork within
the specified range.
Secondary reduction ratio =
Number of rear wheel sprocket
teeth/Number of drive sprocket
teeth
Standard secondary
reduction ratio50/13
(3.846)
* 47/14
(3.357)
* For EUROPE
Part
nameSize Part number
Drive
sprocket
"1"
*(STD) *13T 9383E-13233
(STD) 13T 5TJ-17460-00
* 14T 9383E-14215
** (STD) ** 14T 5NG-17460-00
* For AUS and NZ
** For EUROPE
Part
nameSize Part number
Rear
wheel
sprocket
"2"
** (STD) ** 47T 1C3-25447-00
48T 5GS-25448-50
* 48T 1C3-25448-00
* 49T 1C3-25449-00
(STD) 50T 5TJ-25450-80
* (STD) * 50T 1C3-25450-00
* 51T 1C3-25451-00
52T 5TJ-25452-80
* 52T 1C3-25452-00
* For AUS and NZ
** For EUROPE
Standard tire pressure:
100 kPa (1.0 kgf/cm2,
15 psi)
Extent of adjustment:
60–80 kPa (0.6–0.8 kgf/
cm
2, 9.0–12 psi)
Extent of adjustment:
100–120 kPa (1.0–1.2
kgf/cm
2, 15–18 psi)

4-7
CHASSIS
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
holding 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
holding bolt.
3. Loosen the locknut "1" and make
adjustment by turning the spring
adjuster "2" to achieve the stan-
dard figure from the subtraction of
the length "b" from the length "a".
• 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 reeval-
uation.
• 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-ad-
justment.
SETTING OF SPRING AFTER
REPLACEMENT
After replacement, be sure to adjust
the spring to the set length [sunken
length 90–100 mm (3.5–3.9 in)] and
set it.
1. Use of soft spring
• Set the soft spring for less re-
bound damping to compensate
for its less spring load. Run with
the rebound damping adjuster
one or two clicks on the softer
side and readjust it to suit your
preference.
2. Use of stiff spring
• Set the soft spring for more re-
bound damping to compensate
for its greater spring load. Run
with the rebound damping adjust-
er one or two clicks on the stiffer
side and readjust it to suit your
preference.
Adjusting the rebound damping will
be followed more or less by a change
in the compression damping. For cor-
rection, turn the low compression
damping adjuster on the softer side.
When using a rear shock absorber
other than currently installed, use
the one whose overall length "a"
does not exceed the standard as it
may result in faulty performance.
Never use one whose overall
length is greater than standard.
REAR SHOCK ABSORBER
SETTING PARTS
• Rear shock spring "1"
• The I.D. mark "a" is marked at the
end of the spring.
• Spring specification varies accord-
ing to the color and quantity of I.D.
marks.
• Extent of adjustment (spring pre-
load)
For the spring preload adjustment, re-
fer to "ADJUSTING THE REAR
SHOCK ABSORBER SPRING PRE-
LOAD" in the CHAPTER 3.
Standard figure:
90–100 mm (3.5–3.9 in)
Length "a" of standard
shock:
488.5 mm (19.23 in)
TYPESPRI
NG
RAT
ESPRING
PART
NUM-
BER
(-22212-)I.D.
MARK/
Q'TY
SOFT 4.3 5UN-00 Brown/1
4.5 5UN-10 Green/1
4.7 5UN-20 Red/1
4.9 5UN-30 Black/1
5.1 5UN-40 Blue/1
5.3 5UN-50 Yellow/1
STD 5.5 5UN-60 Pink/1
STIFF5.7 5UN-70 White/1
Maximum Minimum
Position in
which the
spring is turned
in 13 mm (0.51
in) from its free
length.Position in
which the
spring is turned
in 1.5 mm (0.06
in) from its free
length.