2016 YAMAHA WR 450F Owners Manual

HANDLEBAR
5-33
EAS2GC1193
HANDLEBAR
Removing the handlebar
OrderPart name Q’tyRemarks
1 Clutch cable 1 Disconnect.
2 Clutch switch 1
3 Clutch lever holder 1
4 Engine stop switch 1
5 Brake master cylinder 1
6 Throttle cable cap 1
7 Throttle cable (pull) 1 Disconnect.
8 Throttle cable (return) 1 Disconnect.
9 Right grip 1
10 Tube guide 1
11 Start switch 1
12 Left grip 1
13 Handlebar upper holder 2
14 Handlebar 1

HANDLEBAR
5-34
15 Handlebar lower holder2
16 Damper 4
For installation, reverse the removal proce-
dure.
Removing the handlebar
Order Part name Q’tyRemarks

HANDLEBAR
5-35
EAS2GC1194REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:•Clutch switch “1”
TIP
Press the projection, and remove it from the
clutch lever assembly.
3. Remove:• Handlebar grip “1”
TIP
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
4. Remove:
• Throttle cable housings “1”
• Throttle grip “2”
TIP
While removing the throttle cable housing, pull
back the rubber cover “3”.
EAS2GC1195CHECKING THE HANDLEBAR
1. Check:• Handlebar
Bends/cracks/damage  Replace.
EWA
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS2GC1196INSTALLING THE HANDLEBAR
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Damper “1”
• Lower handlebar holders“2” (temporarily)
• Handlebar “3”
• Upper handlebar holders “4”
TIP
• Install the lower handl ebar holders with them
side having the greater distance “a” from the
mounting bolt center facing forward.
• Installing the lower handlebar holders in the
reverse direction allow the front-to-rear offset
amount of the handlebar position to be
changed.
• The upper handlebar holders should be in- stalled with the punch marks “b” facing for-
ward.
• When installing the handlebar, make sure that right and left marks “c” are in place identically
on both sides.
• Install the handlebar so that the projection “d” of the upper handlebar holders is positioned
at the mark on the handlebar as shown.
ECA
Upper handlebar holder bolt28 Nm (2.8 m·kgf, 20 ft·lbf)
T R..

HANDLEBAR
5-36
NOTICE
• First, tighten the bolts on the front side of the upper handlebar holder, and then on
the rear side.
• Turn the handlebar all the way to the left and right. If there is any contact with the
fuel tank, adjust the handlebar position.
3. Tighten:• Lower handlebar holder nut
4. Install: • Handlebar grip “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly coat the handlebar left end with a rubber adhesive.
b. Install the handlebar grip on the handlebar by pressing the grip from the left side.
c. Wipe off any excess adhesive with a clean cloth.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Install the handlebar grip to the handlebar so
that the line “a” between the two arrow marks
faces straight upward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
1
1
a
3
4
Lower handlebar holder nut40 Nm (4.0 m·kgf, 29 ft·lbf)
T R..

HANDLEBAR
5-37
5. Install:• Engine stop switch “1”
• Clutch lever “2”
• Clutch lever holder “3”
•Clamp “4”
TIP
• The engine stop switch, the clutch lever, and the clutch lever holder should be installed ac-
cording to the dimensions shown.
• Pass the engine stop switch lead through the
middle of the clutch lever holder.
6. Install: • Right grip “1”
• Collar “2”Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the grip match mark “b” and tube guide slot “c”
form the angle as shown. 7. Install:
• Rubber cover “1”
• Throttle grip “2”
TIP
Apply the lithium-soap-based grease on the
throttle grip sliding surface.
8. Install:• Throttle cables “1”
TIP
Slightly coat the end of throttle cable and inside
of throttle grip with lithium-soap-based grease.
Then, mount the throttle grip onto the handle-
bar.
9. Install:
• Throttle cable housings “1”
• Screw (throttle cable housings) “2”
EWA
Engine stop switch screw0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch lever holder bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
Screw (throttle cable housings)3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
64
1 b
c
3
64
T R..

HANDLEBAR
5-38
WARNING
After tightening the throttle cable housing
screws, check that the throttle grip “3”
moves smoothly. If it does not, retighten the
screws for adjustment.
10.Install:• Rubber cover “1”
• Cover (throttle cable housings) “2”
11.Install: • Start switch “1”
• Front brake master cylinder assembly “2”
• Front brake master cylinder holder “3”
• Bolt (brake master cylinder holder) “4”
•Clamp “5”
TIP
• Install the brake master cylinder holder with the “UP” mark facing up.
• Install in order for the top of the front brake master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.
12.Install: • Clutch cable “1”
TIP
Before installation, apply the lithium-soap-
based grease to the clutch cable end.
13.Adjust:• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LE-
VER FREE PLAY” on page 3-12.
Front brake master cylinder hold-
er bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T R..
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
2
5
1
4
3
4
1LS

HANDLEBAR
5-39
14.Adjust:• Throttle grip free playRefer to “ADJUSTING THE THROTTLE
GRIP FREE PLAY” on page 3-13.
Throttle grip free play3.0–6.0 mm (0.12–0.24 in)

FRONT FORK
5-40
EAS2GC1197
FRONT FORK
Removing the front fork legs
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Front wheel Refer to “FRONT WHEEL” on page 5-4.
Front brake caliper Refer to “FRONT BRAKE” on page 5-13.
1 Brake hose holder 2
2 Protector 1
3 Upper bracket pinch bolts 2 Loosen.
4 Damper assembly 1 Loosen.
5 Lower bracket pinch bolts 2 Loosen.
6 Front fork leg 1
7 Reflector/Stay/Nut 1 For Canada
For installation, reverse the removal proce-
dure.