2016 YAMAHA WR 450F steering

STEERING HEAD
5-56
TIP
Apply the lithium-soap-based grease on the
bearing and bearing race cover lip.
3. Install:• Lower bracket “1”
TIP
Apply the lithium-soap-based grease on the
bearing, the portion “a” and thread of the steer-
ing stem.
4. Install:• Steering ring nut “1”
TIP
Install the steering nut with its stepped side “a”
facing downward.
Tighten the steering ring nut with a steering
nut wrench “2”.
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-37. 5. Check the steering stem by turning this lock
to lock. If there is any binding, remove the
steering stem and check the steering bear-
ing.
6. Install: • Washer “1”
7. Install: • Front fork “1”
• Upper bracket “2”
TIP
• Temporarily tighten the pinch bolts (lower bracket).
• Do not tighten the pinch bolts (upper bracket)
yet.
8. Install: • Steering stem nut “1”
Steering ring nut
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
LS
1
a
LSLS
T R..
Steering stem nut
145 Nm (14.5 m·kgf, 105 ft·lbf)
T R..

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..

TROUBLESHOOTING
10-3
Cooling system
1. Coolant• Low coolant level
2. Radiator • Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump • Damaged or faulty water pump
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
Fuel system
1. Throttle body • Damaged or loose throttle body joint
2. Air filter • Clogged air filter element
Chassis
1. Brake(s) • Dragging brake
Electrical system
1. Spark plug • Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system • Faulty ECU
• Faulty coolant temperature sensor
EAS2GC1417OVERCOOLING
Cooling system
1. Coolant temperature sensor• Faulty coolant temperature sensor
EAS2GC1418POOR BRAKING PERFORMANCE
Chassis
1. Brake(s)• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Defective master cylinder kit
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS2GC1419FRONT FORK OIL LEAKING
Chassis
1. Front fork• Bent, damaged, or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
EAS2GC1420FAULTY FRONT FORK LEGS
Chassis
1. Front fork • Bent or damaged inner tube
• Bent or damaged outer tube
• Broken fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS2GC1421UNSTABLE HANDLING
Chassis
1. Handlebar• Bent or improperly installed handlebar
2. Steering head components • Improperly installed upper bracket
• Improperly installed lower bracket(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg (s) • Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm • Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly (-ies) • Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire (s) • Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear

TROUBLESHOOTING
10-4
7. Wheel (s)• Incorrect wheel balance
• Broken or loose spoke
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame • Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
EAS2GC1422HEADLIGHT DOES NOT COME ON
Electrical system
1. Headlight• Fuse open circuit
• Wrong headlight bulb
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (start switch)
• Burnt-out headlight bulb
EAS2GC1423HEADLIGHT BULB BURNT OUT
Electrical system
1. Headlight
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty start switch
• Headlight bulb life expired
EAS2GC1424TAILLIGHT DOES NOT COME ON
Electrical system
1. Taillight• Wrong taillight LED
• Too many electrical accessories
• Incorrect connection
• Faulty battery