2016 YAMAHA WR 450F brake pads

REAR WHEEL
5-12
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-based 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 3-31.
6. Tighten: • Rear wheel axle nut “1”
• Locknut “2”
Drive chain slack (on a suitable
stand) 50.0–60.0 mm (1.97–2.36 in)
Wheel axle nut 125 Nm (12.5 m·kgf, 90 ft·lbf)
Locknut 21 Nm (2.1 m·kgf, 15 ft·lbf)
2
1
3
a
T R..
T R..
1
2

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
5-19
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

REAR BRAKE
5-29
EAS2GC1187INSTALLING THE BRAKE CALIPER PISTON
1. Clean:• Brake caliper
• Brake caliper piston seal
• Brake caliper piston dust seal
• Brake caliper pistonUse brake fluid for cleaning.
2. Install: • Brake caliper piston seals “1”
• Brake caliper piston dust seal “2”
EWA
WARNING
Always use new brake caliper piston seal
and brake caliper piston dust seal.
TIP
• Apply the silicone grease on the brake caliper
piston seal and brake caliper piston dust seal.
• Fit the brake caliper piston seals and brake caliper piston dust seals onto the slot on
brake caliper correctly.
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.
EAS2GC1188INSTALLING THE REAR BRAKE CALIPER
1. Install:
• Rear brake caliper
• Rear brake caliper bracket
2. Install: • Rear wheelRefer to “REAR WHEEL” on page 5-9.
• 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 a bend in its pipe portion “a”
is directed as shown and the brake hose
touches the projection “b” on the brake cal-
iper.
3. Install: • Brake pad springs
• Brake pads
• Brake pad pin
• Brake pad pin plug
Refer to “CHECKING THE REAR BRAKE
PADS” on page 3-29.
4. Pour brake fluid to the brake fluid reservoir up to the specified level.
EWA
New
New
2
1
1
a1
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
Brake pad pin 17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake pad pin plug 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Specified brake fluid DOT 4
New
T R..
b
b a
T R..