2016 YAMAHA WR 450F steering

PERIODIC MAINTENANCE
3-8
SWINGARMInspect, lube and
retighten Molybdenum disulfide grease
RELAY ARM, CON-
NECTING ROD Inspect, lube and
retighten Molybdenum disulfide grease
SIDESTAND Lubricate Lithium-soap-based grease
STEERING HEAD Inspect free play
and retighten
Clean and lube Lithium-soap-based grease
Replace bearing
TIRE, WHEELS
Inspect air pres-
sure, wheel run-
out, tire wear and
spoke looseness
Retighten sprocket
bolt
Inspect bearings
Replace bearings
Lubricate Lithium-soap-based grease
THROTTLE, CON-
TROL CABLE
Check routing and
connection
Lubricate Yamaha cable lube or SAE
10W-30 motor oil
ITEM
After
break- in Every
race Every
third (or
500
km) Every
fifth (or
1,000 km) As re-
quired Remarks

PRE-OPERATION INSPECTION AND MAINTENANCE
3-9
EAS2GC1079
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAS2GC1080GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
Coolant Check that coolant is filled up to the radiator cap.
Check the cooling system for leakage. 3-10 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage. 1-28
Engine oil Check that the oil level is correct. Check the crank-
case and oil line for leakage. 3-16 – 18
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly. 3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary. 3-13 – 14
Brakes Check the play of front brake and effect of front and
rear brake. 3-25 – 31
Drive chain Check drive chain slack and alignment. Check that
the drive chain is lubricated properly. 3-31
5-69 – 70
Wheels Check for excessive wear and tire pressure. Check
for loose spokes and have no excessive play. 3-36 – 37
Steering Check that the handlebar can be turned smoothly and
have no excessive play. 3-37 – 38
Front forks and rear
shock absorber Check that they operate smoothly and there is no oil
leakage.
3-31 – 36
Cables (wires) Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and
has no cracks. 3-15 – 16
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is
not loose. 5-10 – 11
Lubrication Check for smooth operation. Lubricate if necessary. 3-14
3-38 – 39
Bolts and nuts Check the chassis and engine for loose bolts and
nuts. 1-32 – 33
Lead connectors Check that the AC magneto, ECU and ignition coil are
connected tightly. 1-9 – 12
Settings Is the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?
4-1 – 8

CHASSIS
3-37
2. Tighten:• SpokesUse a spoke nipple wrench “1” for tighten-
ing.
TIP
• Do not give a half turn (180 °) or more for one tightening.
• Make sure that tightening after a break-in is done until the initial looseness in nipples dis-
appears.
• Make sure that tightening is done in stages,
not at a time.
EAS2GC1121CHECKING THE WHEELS
1. Check: • Wheel(s)Damage/out-of-round  Replace.
EWA
WARNING
Never attempt to make any repairs to the
wheel.
TIP
After replacing a tire or a wheel, always bal-
ance the wheel.
EAS2GC1122CHECKING THE WHEEL BEARINGS
1. Check:
• Wheel bearingsRefer to “CHECKING THE FRONT WHEEL”
on page 5-5 and “CHECKING THE REAR
WHEEL” on page 5-10.
EAS2GC1123CHECKING AND ADJUSTING THE STEER-
ING HEAD
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness  Adjust the steering
head.
3. Remove: • Handlebar
Refer to “HANDLEBAR” on page 5-33.
• Upper bracket Refer to “STEERING HEAD” on page 5-53.
4. Adjust: • Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the washer “1”.
b. After loosening the ring nut “2” with a steer- ing nut wrench “3”, tighten it to the specified
torque.
TIP
• Set the torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of times to check that it moves smoothly.
Spoke nipple wrench (6–7)
90890-01521
Spoke nipple wrench (6–7) YM-01521
Spokes 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
1
T R..
1
3
2

CHASSIS
3-38
c. Turn the front fork to the right and left a few times, and make sure that the steering ro-
tates smoothly. If it does not turn smoothly,
remove the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page 5-53.
d. Loosen the ring nut fully turn and then tight- en it to specification with a steering nut
wrench.
EWA
WARNING
Do not overtighten the lower ring nut.
e. Check the steering head for looseness or binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 5-53.
f. Install the washer “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install: • Upper bracketRefer to “STEERING HEAD” on page 5-53.
• Handlebar
Refer to “HANDLEBAR” on page 5-33.
EAS2GC1124CHECKING AND LUBRICATING THE CA-
BLES
The following procedure applies to all of the in-
ner and outer cables.
EWA
WARNING
Damaged outer cable may cause the cable
to corrode and interfere with its movement.
Replace damaged outer cable and inner ca-
bles as soon as possible.
1. Check:• Outer cableDamage  Replace.
2. Check: • Cable operationRough movement  Lubricate.
TIP
Hold the cable end upright and pour a few
drops of lubricant into the cable sheath or use
a suitable lubricating device.
EAS2GC1125LUBRICATING THE LEVERS
1. Lubricate the pivoting points and metal-to-
metal moving parts of the following parts.
•Brake lever
• Clutch lever
EAS2GC1126LUBRICATING THE PEDAL
1. Lubricate the pivoting point and metal-to-
metal moving parts of the pedal.
Steering nut wrench
90890-01403
Exhaust flange nut wrench YU-A9472
Ring nut (initial tightening torque) 38 Nm (3.8 m·kgf, 27 ft·lbf)
Ring nut (final tightening torque) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T R..
T R..
1
Recommended lubricantEngine oil or a suitable cable lu-
bricant
Recommended lubricant Silicone grease
Recommended lubricant Lithium-soap-based grease
Recommended lubricant Lithium-soap-based grease

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

STEERING HEAD
5-53
EAS2GC1203
STEERING HEAD
Removing the lower bracket
OrderPart name Q’tyRemarks
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-37.
Use a suitable stand to raise the front wheel
off the ground.
Headlight assembly/multi -function meter/front
fender Refer to “GENERAL
CHASSIS” on page 5-1.
Handlebar Refer to “HANDLEBAR” on page 5-33.
1 Front fender 1
2 Steering stem nut 1
3 Front fork leg (s) 2 Refer to “FRONT FORK” on page 5-40.
4 Upper bracket 1
5 Steering ring nut 1
6 Lower bracket 1
7 Bearing race cover 1
8 Upper bearing 1
9 Bearing (lower side) 1
10 Bearing races 2
2
4
5
7
3
(2) (2)
(2)
(2)
(2)
1
6
8
9
10
LS
LS
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.3.8 Nm (0.38 mlbf)
kgf, 2.8 ft
T
.R.3.8 Nm (0.38 mlbf)
kgf, 2.8 ft
T
.R.9 Nm (0.9 mlbf)
kgf, 6.5 ft
T
.R.7 Nm (0.7 mlbf)
kgf, 5.1 ftT
.R.7 Nm (0.7 mlbf)
kgf, 5.1 ft
T
.R.10 Nm (1.0 mlbf)
kgf, 7.2 ft
T
.R.145 Nm (14.5 mlbf)
kgf, 105 ft
T
.R.38 Nm (3.8 mlbf)
kgf, 27 ft
7 Nm (0.7 m
lbf)
kgf, 5.1 ft
*
*

STEERING HEAD
5-54
For installation, reverse the removal proce-
dure.
Removing the lower bracket
OrderPart name Q’tyRemarks
2
4
5
7
3
(2) (2)
(2)
(2)
(2)
1
6
8
9
10
LS
LS
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.21 Nm (2.1 mlbf)
kgf, 15 ft
T
.R.3.8 Nm (0.38 mlbf)
kgf, 2.8 ft
T
.R.3.8 Nm (0.38 mlbf)
kgf, 2.8 ft
T
.R.9 Nm (0.9 mlbf)
kgf, 6.5 ft
T
.R.7 Nm (0.7 mlbf)
kgf, 5.1 ftT
.R.7 Nm (0.7 mlbf)
kgf, 5.1 ft
T
.R.10 Nm (1.0 mlbf)
kgf, 7.2 ft
T
.R.145 Nm (14.5 mlbf)
kgf, 105 ft
T
.R.38 Nm (3.8 mlbf)
kgf, 27 ft
7 Nm (0.7 m
lbf)
kgf, 5.1 ft
*

STEERING HEAD
5-55
EAS2GC1204REMOVING THE LOWER BRACKET
1. Use a suitable stand to raise the front wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:• Rng nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.
EWA
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS2GC1205CHECKING THE STEERING HEAD
1. Wash with kerosene:• Bearing
• Bearing races
2. Check: • Bearing
• Bearing races
Damage/pitting  Replace.
3. Replace:
• Bearing
• Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing race from the steering head pipe with a long rod “1” and a hammer.
b. Remove the bearing race from the lower bracket with a chisel “2” and a hammer.
c. Install a new bearing race.
ECA
NOTICE
If the bearing race is not installed properly,
the steering head pipe could be damaged.
TIP
Always replace the bearing and the bearing
race as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check: • Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAS2GC1206INSTALLING THE STEERING HEAD
1. Install:
• Lower bearing “1”
TIP
Apply the lithium-soap-based grease on the
dust seal lip and bearing inner circumference.
2. Install:• Bearing races
• Upper bearing “1”
• Bearing race cover “2”
Steering nut wrench
90890-01403
Exhaust flange nut wrench YU-A9472