2015 YAMAHA YZ450F brake pads

3
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS.......................................................................... 3-1
MAINTENANCE INTERVALS .................................................................... 3-1
PRE-OPERATION INSPECTION AND MAINTENANCE................................. 3-7
GENERAL INSPECTION AND MAINTENANCE........................................ 3-7
ENGINE............................................................................................................ 3-8
CHECKING THE COOLANT LEVEL .......................................................... 3-8
CHECKING THE COOLING SYSTEM ....................................................... 3-8
CHANGING THE COOLANT...................................................................... 3-8
CHECKING THE RADIATOR CAP ............................................................ 3-9
CHECKING THE RADIATOR CAP OPENING PRESSURE ...................... 3-9
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-10
ADJUSTING THE CLUTCH LEVER POSITION ...................................... 3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-10
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-11
LUBRICATING THE THROTTLE CABLE ................................................ 3-12
CLEANING THE AIR FILTER ELEMENT................................................. 3-12
CHECKING THE THROTTLE BODY JOINT ............................................ 3-13
CHECKING THE BREATHER HOSES .................................................... 3-13
CHECKING THE EXHAUST SYSTEM..................................................... 3-13
CHECKING THE FUEL LINE ................................................................... 3-14
CHECKING THE ENGINE OIL LEVEL..................................................... 3-14
CHANGING THE ENGINE OIL ................................................................ 3-15
ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-16
ADJUSTING THE VALVE CLEARANCE ................................................. 3-17
CHASSIS........................................................................................................ 3-21
BLEEDING THE BRAKE SYSTEM .......................................................... 3-21
CHECKING THE BRAKE HOSE .............................................................. 3-22
ADJUSTING THE FRONT BRAKE .......................................................... 3-22
ADJUSTING THE REAR BRAKE ............................................................. 3-23
CHECKING THE FRONT BRAKE PADS ................................................. 3-23
CHECKING THE REAR BRAKE PADS ................................................... 3-25
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-26
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-26
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-27
CHECKING THE FRONT FORK LEGS ................................................... 3-28
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-28
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................ 3-28
AIR BLEEDING FROM FRONT FORK .................................................... 3-28
ADJUSTING THE FRONT FORK LEGS .................................................. 3-29
CHECKING THE SWINGARM OPERATION ........................................... 3-30
CHECKING THE REAR SUSPENSION ................................................... 3-30
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-30
CHECKING THE TIRES ........................................................................... 3-32
CHECKING AND TIGHTENING THE SPOKES ....................................... 3-32
CHECKING THE WHEELS ...................................................................... 3-33

MAINTENANCE INTERVALS
3-4
FUEL TANK, FUEL
PUMP
Inspect
FUEL HOSE
Inspect
Replace Every four years
FRONT FORK LEG
(S)
Clean Dust seal
Inspect and adjust
Replace oil
Replace oil seal
Clean and grease
oil seals and dust
sealsLithium soap base grease
PROTECTOR
GUIDE
Replace
REAR SHOCK AB-
SORBER
Inspect and adjust
Lubricate(After
rain
ride)Grease pillow balls and bear-
ings.
Retighten Check for tightening torques.
BRAKE(S)
Adjust lever posi-
tion and pedal
height
Lubricate pivot
point
Check brake disc
surface
Check fluid level
and leakage
Retighten brake
disc bolts, caliper
bolts, master cylin-
der bolts and union
boltsCheck for tightening torques.
Replace padsITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks

CHASSIS
3-23
EAS1SL5094ADJUSTING THE REAR BRAKE
1. Check:
• Brake pedal position “a”
(distance from the top of the rider footrest to
the top of the brake pedal)
Out of specification  Regulate.
2. Adjust:
• Brake pedal position
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake pedal position is
obtained.
c. Tighten the locknut.
EWA1DX1001
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before running, bleed the brake
system. Air in the brake system will cause
braking performance to be reduced.
ECA13510
NOTICE
After adjusting the brake pedal position,
make sure that there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SL5095CHECKING THE FRONT BRAKE PADS
1. Measure:
• Brake pad thickness “a”
Out of specification  Replace as a set.
TIP
The pads worn up to the indicator “b” grooves
mean that the brake pad thickness limit is
reached.
2. Replace:
• Brake pads
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the pad pin plug “1”. Brake pedal position
0.0 mm (0.00 in)
Direction “a”
Brake pedal is raised.
Direction “b”
Brake pedal is lowered.
Locknut
6 Nm (0.6 m·kgf, 4.3 ft·lbf)1 2
a
b
T R..
Brake pad lining thickness (inner)
4.4 mm (0.17 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness (outer)
4.4 mm (0.17 in)
Limit
1.0 mm (0.04 in)
a
b
a
1

CHASSIS
3-24
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 plastic hose “5” to the bleed
screw “6” and place a container under the
end of the plastic hose.
f. Loosen the bleed screw and push the brake
caliper piston in.
EWA@
WARNING
Do not reuse the drained brake fluid.
g. Tighten the bleed screw.
h. Install the brake pads “7” and the pad pin.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point.i. Install the brake caliper “8” and tighten the
pad pin “9”.
j. Install the pad pin plug “10”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-26.
4. Check:
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-21. Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
3
2
4
6
5
T R..
Bolt (brake caliper)
28 Nm (2.8 m·kgf, 20 ft·lbf)
Pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
7
a b
T R..
8
9
T R..
10

CHASSIS
3-25
EAS1SL5096CHECKING THE REAR BRAKE PADS
1. Measure:
• Brake pad thickness “a”
Out of specification  Replace as a set.
TIP
The pads worn up to the indicator “b” grooves
mean that the brake pad thickness limit is
reached.
2. Replace:
• Brake pads
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the protector “1” and the pad pin
plug “2”.
b. Loosen the pad pin “3”.
c. Remove the rear wheel “4” and the brake
caliper “5”.
Refer to “REAR WHEEL” on page 4-7.d. Remove the pad pin “6” and the brake pads
“7”.
e. Connect the plastic hose “8” to the bleed
screw “9” and place a container under the
end of the plastic hose.
f. Loosen the bleed screw and push the brake
caliper piston in.
EWA@
WARNING
Do not reuse the drained brake fluid.
g. Tighten the bleed screw.
h. Install the brake pad “10” and the pad pin
“11”.
TIP
• Install the brake pads with their projections “a”
into the brake caliper recesses “b”.
• Temporarily tighten the pad pin at this point. Brake pad lining thickness (inner)
6.4 mm (0.25 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness (outer)
6.4 mm (0.25 in)
Limit
1.0 mm (0.04 in)
ba
a
1 2
Bleed screw
6 Nm (0.6 m·kgf, 4.3 ft·lbf)
34
5
7 6
9
8
T R..

CHASSIS
3-26
i. Install the brake caliper “12” and the rear
wheel “13”.
Refer to “REAR WHEEL” on page 4-7.
j. Tighten the pad pin “14”.
k. Install the pad pin plug “15” and the protector
“16”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-26.4. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-21.
EAS1SL5097CHECKING THE REAR BRAKE PAD INSU-
LATOR
1. Remove:
• Brake pads
Refer to “REAR BRAKE” on page 4-21.
2. Check:
• Rear brake pad insulator “1”
Damage  Replace.
EAS1SL5098CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle upright on a level surface.
TIP
In order to ensure a correct reading of the brake
fluid level, make sure that the top of the brake
fluid reservoir is horizontal.
2. Check:
• Brake fluid level
The minimum level mark “a” or below 
Add.
EWA13090
Pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Pad pin plug
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Bolt (protector)
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
10 11
a
b
T R..
13
14
12
T R..
15
16Recommended brake fluid
DOT 4
A. Front brake
B. Rear brake

FRONT WHEEL
4-6
3. Install:
• Collar “1”
TIP
Apply the lithium soap base grease on the oil
seal lip.
EAS1SL5128INSTALLING THE FRONT WHEEL
1. Install:
• Front wheel
TIP
Install the brake disc “1” between the brake
pads “2” correctly.
2. Install:
• Front wheel axle “1”
TIP
Apply the lithium soap base grease to the front
wheel axle.3. Tighten:
• Front wheel axle nut “1”
ECA14140
NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:
• Front wheel axle pinch bolt “1”
1
LS
Front wheel axle nut
115 Nm (11.5 m·kgf, 83 ft·lbf)
Front wheel axle pinch bolt
21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
1
T R..
1 1

REAR WHEEL
4-10
TIP
Install the brake disc “1” between the brake
pads “2” correctly.
2. Install:
• Drive chain “1”
TIP
Push the rear wheel “2” forward and install the
drive chain.
3. Install:
• Left drive chain puller “1”
• Rear wheel axle “2”
TIP
• Install the left drive chain puller, and insert the
rear wheel axle from the left side.
• Apply the lithium soap base grease to the rear
wheel axle.
4. Install:
• Right drive chain puller “1”
• Washer “2”
• Rear wheel axle nut “3”
TIP
Temporarily tighten the nut (rear wheel axle) at
this point.
5. Adjust:
• Drive chain slack “a”
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-27.
6. Tighten:
• Rear wheel axle nut “1”
• Locknut “2”
1 2
LS
Drive chain slack
50–60 mm (1.97–2.36 in)
Wheel axle nut
135 Nm (13.5 m·kgf, 98 ft·lbf)
Locknut
21 Nm (2.1 m·kgf, 15 ft·lbf)
2
1
3
a
T R..
T R..
1
2