2016 YAMAHA WR 450F Owners Manual

STEERING HEAD
5-57
TIP
Apply the lithium-soap-based grease to the
contact surface of the steering stem nut when
installing.
9. After tightening the nut, check the steering for smooth movement. If not, adjust the
steering by loosening the steering ring nut
little by little.
10.Adjust:
• Front fork top end “a”
11.Tighten: • Pinch bolt (upper bracket) “1”
• Pinch bolt (lower bracket) “2”
EWA
WARNING
Tighten the lower bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction. 12.Install:
• Speed sensor lead holder “1”
• Speed sensor lead clamp “2”
TIP
• Insert the end of the speed sensor lead holder
in the hole in the lower bracket “a”.
• Install so that the marking “b” on the speed sensor lead aligns with the speed sensor lead
holder edge.
• Install the speed sens or lead clamp while in-
serting it in the hole “c” in the speed sensor
lead holder.
Front fork top end (standard) “a”
5 mm (0.20 in)
Upper bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf)
a
T R..
T R..
Speed sensor lead holder bolt13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Speed sensor lead clamp bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
2 1
T R..

REAR SHOCK ABSORBER ASSEMBLY
5-58
EAS2GC1207
REAR SHOCK ABSORBER ASSEMBLY
Removing the rear shock absorber assembly
OrderPart name Q’tyRemarks
Seat Refer to “GENERAL CHASSIS” on page 5-1.
Side cover (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 5-1.
Fuel tank Refer to “FUEL TANK” on page 8-1.
1 Rear shock absorber assembly lower bolt 1
2 Rear shock absorber assembly upper bolt 1
3 Rear shock absorber assembly 1
4 Locknut 1
5 Adjusting nut 1
6 Lower spring guide 1
7 Upper spring guide 1
8Spring 1
9 Dust seal 2
10 Collars 2
11 Bushing 1
2
12
1615
14 13
12
14
4
5
7
6
8 3
9
9
10
10
11
1
New
New
13New
LS
LS
M
M
M
M
M

REAR SHOCK ABSORBER ASSEMBLY
5-59
12 Collars2
13 O-ring 2
14 Dust seal 2
15 Stopper ring 1
16 Bearing 1
For installation, reverse the removal proce-
dure.
Removing the rear shock absorber assembly
Order Part name Q’tyRemarks
2
12
1615
14 13
12
14
4
5
7
6
8 3
9
9
10
10
11
1
New
New
13New
LS
LS
M
M
M
M
M

REAR SHOCK ABSORBER ASSEMBLY
5-60
Disassembling the relay arm
OrderPart name Q’tyRemarks
1 Relay arm 1
2 Connecting arm 1
3Collars 3
4Oil seals 6
5Washers 8
6 Bearing 6
For assembly, reverse the disassemble pro-
cedure.
5
3
5
6
165
4
5
5
4
56
6
5
4
3
2
4
6
6
3
4
4
T.R.80 Nm (8.0 mlbf)
kgf, 58 ft
M
M
M
M
M
M M

REAR SHOCK ABSORBER ASSEMBLY
5-61
EAS2GC1208HANDLING THE REAR SHOCK ABSORBEREWA
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure that you understand the following in-
formation. The manufacturer cannot be held
responsible for property damage or person-
al injury that may result from improper han-
dling of the rear shock absorber.
• Do not tamper or attempt to open the rear shock absorber.
• Do not subject the rear shock absorber to an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.
EAS2GC1209DISPOSING OF A REAR SHOCK ABSORB-
ER
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA
WARNING
• Wear protective glasses to prevent your
eyes from damage due to possible gas or
metal chips scattered.
• To dispose of a damaged or a worn-out rear shock absorber, take the unit to your
Yamaha dealer for this disposal proce-
dure.
EAS2GC1210REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
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 shock absorber assembly lower bolt
“1”
TIP
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly
EAS2GC1211REMOVING THE BEARING
1. Remove:• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer
race and remove the stopper ring.
1
1

REAR SHOCK ABSORBER ASSEMBLY
5-62
2. Remove:• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS2GC1212CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:• Rear shock absorber rod
Bends/damage  Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
•Spring
Damage/wear  Replace. • Spring guide
Damage/wear  Replace.
• Bearing
Damage/wear  Replace.
•Bolts Bends/damage/wear  Replace.
EAS2GC1213CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear  Replace.
2. Check: • Bearing
• Spacers
Damage/pitting/scratches  Replace the
bearings and spacers as a set.
3. Check: • Oil sealsDamage/pitting  Replace.
EAS2GC1214INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install: • Bearing “1”
• Washer “2”
• Oil seals “3” (to relay arm “4”)
1
Recommended lubricantMolybdenum disulfide grease
Installed depth “a” 0 mm (0 in)
New
3
3
43
2 2
2 2
a
1 1 1

REAR SHOCK ABSORBER ASSEMBLY
5-63
3. Install:• Bearing “1”
• Oil seals “2” (to connecting arm “3”)
EAS2GC1215INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY
1. Lubricate:• Bearing (lower side)
•Dust seal
•Collars
• Bushing
ECA
NOTICE
Do not apply the grease to the bearing outer
race because it will wear the rear shock ab-
sorber surface on which the bearing is
press fitted.
2. Lubricate:• O-ring
3. Install: • Bearing
• Stopper ring (to rear shock absorber assembly (upper
side))
TIP
• Install the bearing parallel until the stopper ring groove appears by pressing its outer
race.
• After installing the stopper ring, push back the
bearing unit it contacts the stopper ring. 4. Install:
• Bearing “1”
• Bushing “2”
• Collar “3”
• Dust seal “4”(to rear shock absorber assembly (lower
side))
TIP
Install the dust seals with their lips facing in-
ward.
5. Lubricate:
• Connecting arm and frame bolt
• Relay arm and connecting arm bolt
• Relay arm and swingarm bolt(circumference and threaded portion)
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly lower bolt
6. Install: • Rear shock absorber assembly
TIP
• When installing the rear shock absorber as-sembly, lift up the swingarm.
• Install the rear shock absorber assembly up- per bolt, and connecting arm bolt (frame side)
from the right.
• Install the rear shock absorber assembly low- er bolts, connecting arm bolt (relay arm side),
and relay arm bolt (swingarm side) from the
left.
Installed depth “a”
0 mm (0 in)
Recommended lubricant Molybdenum disulfide grease
Recommended lubricant Lithium-soap-based grease
New
3
a
1
1 2
a
2
New
Installed depth “a” 4.25 mm (0.17 in)
Recommended lubricant Molybdenum disulfide grease

REAR SHOCK ABSORBER ASSEMBLY
5-64
7. Tighten:• Rear shock absorber assembly upper bolt
• Connecting arm bolt (frame side)
• Connecting arm bolt (relay arm side)
• Relay arm bolt (swingarm side)
• Rear shock absorber assembly lower bolt Rear shock absorber assembly
upper bolt
56 Nm (5.6 m·kgf, 41 ft·lbf)
Connecting arm bolt (frame side) 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (relay arm
side) 80 Nm (8.0 m·kgf, 58 ft·lbf)
Relay arm bolt (swingarm side) 70 Nm (7.0 m·kgf, 51 ft·lbf)
Rear shock absorber assembly
lower bolt 53 Nm (5.3 m·kgf, 38 ft·lbf)
T R..
T R..
T R..
T R..
T R..