2016 YAMAHA WR 450F Owners Manual

CHASSIS
4-4
TIP
• 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 reevalua-
tion.
• If the standard figure cannot be achieved by adjusting the adjuster and changing the set
length, replace the spri ng with an optional one
and make readjustment.
EAS2GC1146SETTING OF SPRING AFTER REPLACE-
MENT
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
• Adjust to decrease rebound damping force to compensate for less spring load. Run with
the rebound damping force adjuster one or
two clicks turned out, and readjust it to suit
your preference.
2. Use of stiff spring • Adjust to increase rebound damping force to
compensate for greater spring load. Run
with the rebound damping force adjuster
one or two clicks turned in, and readjust it to
suit your preference.
TIP
Adjusting the rebound damping force will be fol-
lowed more or less by a change in the com-
pression damping force. For correction, adjust
to decrease compression damping force.
EWA
WARNING
When using a rear shock absorber other
than currently installed, use the one whose
overall length “a” does not exceed the stan-
dard as it may result in faulty performance.
Never use one whose overall length is
greater than standard.
EAS2GC1147REAR SHOCK ABSORBER SETTING
PARTS
• Rear shock spring “1”
TIP
• The I.D. mark “a” is marked at the end of the spring.
• Spring specification varies according to the
color of I.D. marks.
Length “a” of standard shock 462.5 mm (18.21 in)
Type Spring
rate N/ mm Part number
I.D.
Mark
SOFT 48
2GB-22212-10
(Blue) Black
50 2GB-22212-00
(Blue) Green
52 1SL-22212-40
(Blue) Yellow
B11-22212-00 (Yellow) Blue
54 1SL-22212-60
(Blue) Pink
B11-22212-10
(Yellow)
STD 56 1SL-22212-20
(Blue) White
B11-22212-20
(Yellow)
STIFF 58
1SL-22212-00
(Blue) Silver
B11-22212-30
(Yellow)
60 1SL-22212-80
(Blue) Brown
B11-22212-40
(Yellow)

CHASSIS
4-5
• Spring preload adjusting positions
TIP
For the spring preload adjustment, refer to “AD-
JUSTING THE REAR SHOCK ABSORBER
ASSEMBLY” on page 3-34.Spring preload adjusting positions
MinimumPosition in which the spring is
turned in 1.5 mm (0.06 in) from
its free length.
Standard Position in which the spring is
turned in 12 mm (0.47 in) from its
free length.
Maximum Position in which the spring is
turned in 18 mm (0.71 in) from its
free length.

CHASSIS
4-6
EAS2GC1148SUSPENSION SETTING (FRONT FORK)
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absor ber sunken length to the standard figure 90–100 mm
(3.5–3.9 in).
Symptom Section
CheckAdjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff over entire
range Compression
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil amount Decrease oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with soft spring.
Unsmooth
movement over
entire range Outer tube
Inner tube
Check for any bends, dents,
other noticeable scars, etc. If
any, replace affected parts.
Slide metal Replace with a new one for ex- tended use.
Piston metal Replace with a new one for ex- tended use.
Lower bracket
tightening
torque Retighten to specified torque.
Poor initial
movement Rebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Oil seals Apply grease in oil seal wall.
Soft over entire
range, bottom-
ing out Compression
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Oil amount Increase oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Spring Replace with stiff spring.
Stiff toward
stroke end Oil amountDecrease oil amount by about
5 cm
3 (0.2 US oz, 0.2 Imp.oz).
Soft toward
stroke end, bot-
toming out Oil amountIncrease oil amount by about 5
cm
3 (0.2 US oz, 0.2 Imp.oz).
Stiff initial
movement Compression
damping forceTurn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.

CHASSIS
4-7
EAS2GC1149SUSPENSION SETTING (REAR SHOCK ABSORBER)
TIP
• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2- click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.Low front, tend-
ing to lower
front posture
Compression
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Rebound
damping force Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Balance with
rear end Set sunken length for 95–100
mm (3.7–3.9 in) when one
passenger is astride seat (low-
er rear posture).
Oil amount Increase oil amount by about 5 cm
3 (0.2 US oz, 0.2 Imp.oz).
“Obtrusive”
front, tending to
upper front pos-
ture Compression
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Balance with
rear end Set sunken length for 90–95
mm (3.5–3.7 in) when one
passenger is astride seat (up-
per rear posture).
Spring Replace with soft spring.
Oil amount Decrease oil amount by about 5–10 cm
3 (0.2–0.3 US oz, 0.2–
0.4 Imp.oz).
Symptom Section
Check Adjust
Jump Large
gap Medi-
um
gap Small
gap
Stiff, tending to
sink Rebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Spring set
length Set sunken length for 90–100
mm (3.5–3.9 in) when one
passenger is astride seat.
Spongy and un-
stable Rebound
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Low compres-
sion damping Turn adjuster clockwise (about
1 click) to increase damping.
Spring Replace with stiff spring.
Symptom
Section
Check Adjust
Jump Large
gap Medi-
um
gap Small
gap

CHASSIS
4-8
Heavy and
draggingRebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Spring Replace with soft spring.
Poor road grip-
ping Rebound
damping force
Turn adjuster counterclock-
wise (about 2 clicks) to de-
crease damping.
Low compres-
sion damping Turn adjuster clockwise (about
1 click) to increase damping.
High compres-
sion damping Turn adjuster clockwise (about
1/6 turn) to increase damping.
Spring set
length Set sunken length for 90–100
mm (3.5–3.9 in) when one
passenger is astride seat.
Spring Replace with soft spring.
Bottoming out High compres-
sion damping
Turn adjuster clockwise (about
1/6 turn) to increase damping.
Spring set
length Set sunken length for 90–100
mm (3.5–3.9 in) when one
passenger is astride seat.
Spring Replace with stiff spring.
Bouncing Rebound
damping force
Turn adjuster clockwise (about
2 clicks) to increase damping.
Spring Replace with soft spring.
Stiff travel High compres-
sion damping
Turn adjuster counterclock-
wise (about 1/6 turn) to de-
crease damping.
Spring set
length Set sunken length for 90–100
mm (3.5–3.9 in) when one
passenger is astride seat.
Spring Replace with soft spring.
Symptom
Section
CheckAdjust
Jump Large
gap Medi-
um
gap Small
gap

CHASSIS
4-9

5
CHASSIS
GENERAL CHASSIS........................................................................................ 5-1
REMOVING THE LEFT SIDE COVER ....................................................... 5-3
REMOVING THE SEAT ............................................................................. 5-3
FRONT WHEEL ................................................................................................ 5-4
REMOVING THE FRONT WHEEL............................................................. 5-5
CHECKING THE FRONT WHEEL ............................................................. 5-5
DISASSEMBLING THE FRONT WHEEL ................................................... 5-6
ASSEMBLING THE FRONT WHEEL ......................................................... 5-6
INSTALLING THE FRONT WHEEL ........................................................... 5-7
REAR WHEEL .................................................................................................. 5-9
REMOVING THE REAR WHEEL ............................................................. 5-10
CHECKING THE REAR WHEEL.............................................................. 5-10
DISASSEMBLING THE REAR WHEEL ................................................... 5-10
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .......... 5-10
ASSEMBLING THE REAR WHEEL ......................................................... 5-11
INSTALLING THE REAR WHEEL............................................................ 5-11
FRONT BRAKE .............................................................................................. 5-13
INTRODUCTION ...................................................................................... 5-17
CHECKING THE FRONT BR AKE DISC .................................................. 5-17
REMOVING THE FRONT BRAKE CALIPER ........................................... 5-17
DISASSEMBLING THE FRONT BR AKE CALIPER................................. 5-17
CHECKING THE FRONT BR AKE CALIPER ........................................... 5-18
ASSEMBLING THE FRONT BR AKE CALIPER ....................................... 5-18
INSTALLING THE BRAKE CALIPER PISTON ........................................ 5-18
INSTALLING THE FRONT BR AKE CALIPER ......................................... 5-19
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................ 5-20
CHECKING THE FRONT BRAKE MASTER CYLINDER......................... 5-20
ASSEMBLING THE FRONT BRAKE M ASTER CYLINDER .................... 5-20
INSTALLING THE FRONT BRAKE MASTER CYLINDER....................... 5-21
REAR BRAKE ................................................................................................ 5-23
INTRODUCTION ...................................................................................... 5-27
CHECKING THE REAR BRAKE DISC............................. ........................ 5-27
REMOVING THE REAR BRAKE CALIPER ............................................. 5-28
DISASSEMBLING THE REAR BR AKE CALIPER ................................... 5-28
CHECKING THE REAR BRAKE CALIPER .............................................. 5-28
ASSEMBLING THE REAR BRAKE CALIPER ......................................... 5-28
INSTALLING THE BRAKE CALIPER PISTON ........................................ 5-29
INSTALLING THE REAR BRAKE CALIPER .................... ........................ 5-29
REMOVING THE REAR BRAKE MASTER CYLINDER .......................... 5-30
CHECKING THE REAR BRAKE MASTER CYLINDER ........................... 5-30
ASSEMBLING THE REAR BRAKE M ASTER CYLINDER....................... 5-30
INSTALLING THE REAR BRAKE MASTER CYLINDER ......................... 5-31

HANDLEBAR................................................................................................. 5-33
REMOVING THE HANDLEBAR ............................................................... 5-35
CHECKING THE HANDLEBAR ............................................................... 5-35
INSTALLING THE HANDLEBAR ............................................................. 5-35
FRONT FORK ................................................................................................. 5-40
REMOVING THE FRONT FORK LEGS ................................................... 5-42
DISASSEMBLING THE FRONT FO RK LEGS ......................................... 5-42
CHECKING THE FRONT FORK LEGS ................................................... 5-43
ASSEMBLING THE FRONT FORK LEGS ............................................... 5-44
INSTALLING THE FRONT FORK LEGS ................................................. 5-50
STEERING HEAD ........................................................................................... 5-53
REMOVING THE LOWER BRACKET...................................................... 5-55
CHECKING THE STEERING HEAD ........................................................ 5-55
INSTALLING THE STEERING HEAD ...................................................... 5-55
REAR SHOCK ABSORBER ASSEMBLY ..................................................... 5-58
HANDLING THE REAR SHOCK ABSORBER ......................................... 5-61
DISPOSING OF A REAR SH OCK ABSORBER ...................................... 5-61
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................... 5-61
REMOVING THE BEARING..................................................................... 5-61
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................... 5-62
CHECKING THE CONNECTING ARM AND RELAY ARM ...................... 5-62
INSTALLING THE RELAY ARM............................................................... 5-62
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY .................. 5-63
SWINGARM .................................................................................................... 5-65
REMOVING THE SWINGARM................................................................. 5-66
REMOVING THE BEARING..................................................................... 5-66
CHECKING THE SWINGARM ................................................................. 5-66
INSTALLING THE SWINGARM ............................................................... 5-67
CHAIN DRIVE ................................................................................................. 5-68
REMOVING THE DRIVE CHAIN.............................................................. 5-69
CHECKING THE DRIVE CHAIN .............................................................. 5-69
CHECKING THE DRIVE SPROCKET...................................................... 5-70
CHECKING THE REAR WHEEL SPROCKET ......................................... 5-70
INSTALLING THE DRIVE CHAIN ............................................................ 5-70