2016 YAMAHA WR 450F washer fluid

MOTORCYCLE CARE AND STORAGE
1-34
EAS2GC1058
MOTORCYCLE CARE AND STOR-
AGE
EAS2GC1059CARE
While the open design of a motorcycle reveals
the attractiveness of the technology, it also
makes it more vulnerable. Rust and corrosion
can develop even if high-quality components
are used. A rusty exhaust pipe may go unno-
ticed on a car, however, it detracts from the
overall appearance of a motorcycle. Frequent
and proper care does not only comply with the
terms of the warranty, but it will also keep your
motorcycle looking good, extend its life and op-
timize its performance.
Before cleaning
1. Cover the muffler outlet with a plastic bag af-ter the engine has cooled down.
2. Make sure that all caps and covers as well as all electrical coup lers and connectors, in-
cluding the spark plug cap, are tightly in-
stalled.
3. Remove extremely stubborn dirt, like oil
burnt onto the crankcase, with a degreasing
agent and a brush, but never apply such
products onto seals, gaskets, sprockets, the
drive chain and wheel axles. Always rinse
the dirt and degreaser off with water.
Cleaning
ECA
NOTICE
• Avoid using strong acidic wheel cleaners, especially on spoked wheels. If such prod-
ucts are used on hard-to-remove dirt, do
not leave the cleaner on the affected area
any longer than instructed. Also, thor-
oughly rinse the area off with water, imme-
diately dry it, and then apply a corrosion
protection spray.
• Improper cleaning can damage plastic parts (such as cowlings, panels, wind-
shields, headlight lenses, meter lenses,
etc.) and the mufflers. Use only a soft,
clean cloth or sponge with water to clean
plastic. However, if the plastic parts can-
not be thoroughly cleaned with water, di-
luted mild detergent with water may be
used. Be sure to rinse off any detergent
residue using plenty of water, as it is
harmful to plastic parts. • Do not use any harsh chemical products
on plastic parts. Be sure to avoid using
cloths or sponges which have been in con-
tact with strong or abrasive cleaning prod-
ucts, solvent or thinner, fuel (gasoline),
rust removers or inhibitors, brake fluid,
antifreeze or electrolyte.
• Do not use high-pressure washers or steam-jet cleaners since they cause water
seepage and deterioration in the following
areas: seals (of wheel and swingarm bear-
ings, fork and brakes), electric compo-
nents (couplers, connectors, instruments,
switches and lights), breather hoses and
vents.
• For motorcycles equipped with a wind-
shield: Do not use strong cleaners or hard
sponges as they will cause dulling or
scratching. Some cleaning compounds for
plastic may leave scratches on the wind-
shield. Test the product on a small hidden
part of the windshield to make sure that it
does not leave any marks. If the wind-
shield is scratched, use a quality plastic
polishing compound after washing.
After normal use
Remove dirt with warm water, a mild detergent,
and a soft, clean sponge, and then rinse thor-
oughly with clean water. Use a toothbrush or
bottlebrush for hard-to-reach areas. Stubborn
dirt and insects will come off more easily if the
area is covered with a wet cloth for a few min-
utes before cleaning.
After riding in the rain, near the sea or on salt-
sprayed roads
Since sea salt or salt sprayed on roads during
winter are extremely corrosive in combination
with water, carry out the following steps after
each ride in the rain, near the sea or on salt-
sprayed roads.
TIP
Salt sprayed on roads in the winter may remain
well into spring.
1. Clean the motorcycle with cold water and a mild detergent, after the engine has cooled
down.
NOTICE: Do not use warm water since it
increases the corrosive action of the salt.

FRONT BRAKE
5-13
EAS2GC1167
FRONT BRAKE
Removing the front brake caliper
OrderPart name Q’tyRemarks
Brake fluid Drain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-25.
1 Union bolt 1
2 Copper washers 2
3 Front brake hose 1
4 Brake pad pin plug 1
5 Brake pad pin 1
6 Brake pads 2
7 Brake pad spring 1
8 Front brake caliper assembly 1
9 Front brake caliper bracket 1
For installation, reverse the removal proce-
dure.
3
9
1
2
8
4
5
7
6
T.R.30 Nm (3.0 mlbf)
kgf, 22 ft
T.R.23 Nm (2.3 mlbf)
kgf, 17 ft
T.R.17 Nm (1.7 mlbf)
kgf, 12 ft
T.R.2.5 Nm (0.25 mlbf)
kgf, 1.8 ft
T.R.6 Nm (0.6 mlbf)
kgf, 4.3 ft

FRONT BRAKE
5-15
Removing the front brake master cylinder
OrderPart name Q’tyRemarks
Brake fluid Drain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-25.
1 Brake lever 1
2 Union bolt 1
3 Copper washers 2
4 Front brake hose 1
5 Brake master cylinder reservoir cap 1
6 Brake master cylinder reservoir diaphragm 1
7 Front brake master cylinder float 1
8 Front brake master cylinder holder 1
9 Front brake master cylinder 1
For installation, reverse the removal proce-
dure.
5
6
7
2 3
4 8
9
1
T.R.30 Nm (3.0 mlbf)
kgf, 22 ft
T.R.1.5 Nm (0.15 mlbf)
kgf, 1.1 ft
T.R.6 Nm (0.6 mlbf)
kgf, 4.3 ft
T.R.6 Nm (0.6 mlbf)
kgf, 4.3 ft

FRONT BRAKE
5-17
EAS2GC1168INTRODUCTIONEWA
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components unless absolutely necessary.
• If there is any problem with connections on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the
brake fluid, and clean it. After that, add a
suitable amount of brake fluid. Then, bleed
it after reassembly.
• Use only brake fluid for washing brake
components.
• Use new brake fluid for cleaning the brake components.
• Immediately wipe off the spilled brake fluid to avoid damage to painted surfaces or
plastic parts.
• Handle brake fluid with special care not to let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS2GC1169CHECKING THE FRONT BRAKE DISC
1. Remove: • Front wheel
Refer to “FRONT WHEEL” on page 5-4.
2. Check: • Front brake disc
Damage/galling  Replace.
3. Measure: • Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace. 4. Install:
• Front wheelRefer to “FRONT WHEEL” on page 5-4.
EAS2GC1170REMOVING THE FRONT BRAKE CALIPER
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:• Union bolt
• Copper washers
• Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid.
EAS2GC1171DISASSEMBLING THE FRONT BRAKE CAL-
IPER
1. Remove:• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seals “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening to force out the piston from the
brake caliper.
EWA
WARNING
• Cover the brake caliper piston with a rag. Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
Brake disc thickness limit 2.5 mm (0.10 in)
3
2
1

FRONT BRAKE
5-19
3. Install:• Brake caliper piston “1”
TIP
Apply the brake fluid on the piston outer sur-
face.
ECA
NOTICE
• Install the piston with its side “a” facing the brake caliper.
• Never force to insert.
EAS2GC1175INSTALLING THE FRONT BRAKE CALIPER
1. Install:• Front brake caliper bracket
• Front brake caliper(temporarily)
• Copper washers
• Brake hose
• Union bolt
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
NOTICE
Make sure that the pipe portion “a” of the
brake hose touches the projection “b” on
the brake caliper. 2. Install:
• Front brake caliper
• Brake pad spring
• Brake pad
• Brake pad pin
• Brake hose holder
Refer to “CHECKING THE FRONT BRAKE
PADS” on page 3-27.
3. Tighten: • Brake hose holder nut “1”
TIP
Make sure that the brake hose holder “2” is in-
stalled with its upper end “a” aligned with the
paint “b” on the brake hose.
4. Pour brake fluid to the brake master cylinder reservoir up to the specified level.
EWA
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
Front brake caliper bracket23 Nm (2.3 m·kgf, 17 ft·lbf)
Brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf)
1
a1
New
T R..
a
b
Brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake hose holder nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Specified brake fluid DOT 4
T R..
T R..
1
2
b
a

FRONT BRAKE
5-20
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:• Brake systemRefer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
6. Check: • Brake fluid level
The minimum level mark or below  Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30.
7. Check: • Brake lever free playRefer to “ADJUSTING THE FRONT
BRAKE” on page 3-26.
• Brake lever operation A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
EAS2GC1176REMOVING THE FRONT BRAKE MASTER
CYLINDER
TIP
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake
system.
1. Remove: • Union bolt
• Copper washers
• Brake hoses
TIP
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EAS2GC1177CHECKING THE FRONT BRAKE MASTER
CYLINDER
1. Check:• Brake master cylinder “1”Damage/scratches/wear  Replace.
• Brake fluid delivery passages “2”
(brake master cylinder body)
Obstruction  Blow out with compressed
air. 2. Check:
• Brake master cylinder kit
Damage/scratches/wear  Replace.
3. Check: • Brake master cylinder reservoir cap
4. Check: • Brake hosesCracks/damage/wear  Replace.
EAS2GC1178ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER
EWA
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.
1. Wash the brake master cylinder and the brake master cylinder kit with brake fluid.
2. Install: • Primary cylinder cup “1”
• Secondary cylinder cup “2”
Install to the brake master cylinder piston
“3”.
EWA
WARNING
Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance. Specified brake fluid
DOT 4
1
2

FRONT BRAKE
5-21
3. Install:• Spring “1” Install to the brake master cylinder piston
“2”.
TIP
Install the spring with a smaller inside diameter
to the brake master cylinder piston.
4. Install:• Brake master cylinder kit “1”
• Washer “2”
• Circlip “3”
• Dust boot “4”
• Push rod “5”
TIP
• Before installation, apply brake fluid to the
brake master cylinder kit.
• Before installation, apply silicone grease to the push rod end.
• Use circlip pliers to install the circlip.
EAS2GC1179INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder “1”
TIP
• Install the front brake master cylinder holder with the “UP” mark facing up.
• First, tighten the upper bolt, then the lower
bolt.
2. Install: • Copper washers
• Brake hose
• Union bolt
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
NOTICE
During installation, bring the brake hose
into contact with the brake master cylinder
projection “a” and make its bent portion “b”
face downward.
12
3
2
1
3
New
New
Brake master cylinder holder bolt9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf)
T R..
1
New
T R..

REAR BRAKE
5-23
EAS2GC1180
REAR BRAKE
Removing the rear brake caliper
OrderPart name Q’tyRemarks
Brake fluid Drain.
Refer to “BLEEDING THE BRAKE SYSTEM”
on page 3-25.
1 Protector 1
2 Union bolt 1
3 Copper washers 2
4 Rear brake hose 1
5 Brake pad pin plug 1
6 Brake pad pin 1
7 Rear brake pad assembly 2
8 Rear brake caliper bracket 1
9 Brake pad springs 2
10 Rear brake disc cover 1
11 Rear brake caliper assembly 1
For installation, reverse the removal proce-
dure.
2
3 4
11
5 6
7 9
1
8
9
10
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)T.R.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)T.R.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)T.R.
17 Nm (1.7 m•kgf, 12 ft•Ibf)T.R.
30 Nm (3.0 m•kgf, 22 ft•Ibf)T.R.
New
S
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)T.R.