2016 YAMAHA WR 450F Owners Manual

REAR WHEEL
5-9
EAS2GC1160
REAR WHEEL
Removing the rear wheel
OrderPart name Q’tyRemarks
Use a suitable stand to raise the rear wheel
off the ground.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1
5Collars 2
6 Rear wheel sprocket 1
7Oil seals 2
8 Circlip 1
9 Bearing 3
10 Brake disc 1
For installation, reverse the removal proce-
dure.
(6)
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
2
5
7
9
LS
LS(6)
4 6
1
(6)
3
LS
8
9
10
7
5
LT
14 Nm (1.4 m kgf, 10 ft Ibf)T.R.
3
21 Nm (2.1 m kgf, 15 ft Ibf)T.R.
50 Nm (5.0 m kgf, 36 ft Ibf)T.R.
125 Nm (12.5 m kgf, 90 ft lbf)T.R.

REAR WHEEL
5-10
EAS2GC1161REMOVING THE REAR WHEEL
1. Use a suitable stand to raise the rear wheel off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:• Rear wheel axle nut “1”
3. Loosen:
• Locknut “2”
4. Tighten: • Adjusting bolt “3”
5. Remove: • Rear wheel axle
• Rear wheel
TIP
• Push the rear wheel forward and remove the drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.
EAS2GC1162CHECKING THE REAR WHEEL
1. Check:
• Rear wheel axle
• Rear wheel
• Bearing
• Oil sealsRefer to “CHECKING THE FRONT WHEEL”
on page 5-5.
2. Check: •Tire(s)
• Rear wheelDamage/wear  Replace.
Refer to “CHECKING THE TIRES” on page
3-36 and “CHECKING THE WHEELS” on
page 3-37.
3. Check: • Spokes
Refer to “CHECKING THE FRONT WHEEL”
on page 5-5. 4. Measure:
• Radial wheel runout
• Lateral wheel runoutRefer to “CHECKING THE FRONT WHEEL”
on page 5-5.
EAS2GC1163DISASSEMBLING THE REAR WHEEL
1. Remove:• Oil seals
• Bearing
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 5-6.
EAS2GC1164CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:• Rear wheel sprocketMore than 1/4 tooth wear “a”  Replace the
rear wheel sprocket and the drive sprocket
as a set.
Bent tooth  Replace the rear wheel
sprocket and the drive sprocket as a set.
2. Replace: • Rear wheel sprocket
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the rear wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
3
1 2
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
b. Correct
1. Drive chain roller
2. Rear wheel sprocket
Rear wheel sprocket self-locking
nut50 Nm (5.0 m·kgf, 36 ft·lbf)
T R..

REAR WHEEL
5-11
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1165ASSEMBLING THE REAR WHEEL
1. Install:• Bearing (right side) “1”
• Circlip “2”
• Spacer “3”
• Bearing (left side) “4”
• Oil seals “5”
TIP
• Apply the lithium-soap-based grease to the bearing and the oil seal lip when installing.
• Install the bearing with seal facing outward.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s
marks or numbers facing outward.
ECA
NOTICE
Install the bearing by pressing its outer race
parallel.
TIP
Use a socket “1” that matches the diameter of
the bearing outer race and that of the oil seal. 2. Install:
• Brake disc “1”
• Brake disc bolt “2”
TIP
Tighten the bolts in stages and in a crisscross
pattern.
3. Install:• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
EAS2GC1166INSTALLING THE REAR WHEEL
1. Install:
• Rear wheel
New
New
5
43
1
25
LSLS
Brake disc bolt
14 Nm (1.4 m·kgf, 10 ft·lbf)
LOCTITE®
1
T R..
1
LS

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
5-14
Disassembling the front brake caliper
OrderPart name Q’tyRemarks
1 Brake caliper piston 2
2 Brake caliper piston dust seal 2
3 Brake caliper piston seal 2
4 Bleed screw 1
For assembly, reverse the disassemble pro-
cedure.
1 2
34
S
S
BF
BFT R..
S
6 Nm (0.6 m kgf, 4.3 ft Ibf)

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
5-16
Disassembling the front brake master cylinder
OrderPart name Q’tyRemarks
1 Push rod 1
2 Dust boot 1
3 Circlip 1
4Washer 1
5 Brake master cylinder kit 1
For assembly, reverse the disassemble pro-
cedure.
BF
5
4
3
2
1
S
New
New