2016 YAMAHA WR 450F lock

REAR WHEEL
5-11
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
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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
5-19
3. Install:• Brake caliper piston “1”
TIP
Apply the brake fluid on the piston outer sur-
face.
ECA
NOTICE
• Install the piston with its side “a” facing the brake caliper.
• Never force to insert.
EAS2GC1175INSTALLING THE FRONT BRAKE CALIPER
1. Install:• Front brake caliper bracket
• Front brake caliper(temporarily)
• Copper washers
• Brake hose
• Union bolt
EWA
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA
NOTICE
Make sure that the pipe portion “a” of the
brake hose touches the projection “b” on
the brake caliper. 2. Install:
• Front brake caliper
• Brake pad spring
• Brake pad
• Brake pad pin
• Brake hose holder
Refer to “CHECKING THE FRONT BRAKE
PADS” on page 3-27.
3. Tighten: • Brake hose holder nut “1”
TIP
Make sure that the brake hose holder “2” is in-
stalled with its upper end “a” aligned with the
paint “b” on the brake hose.
4. Pour brake fluid to the brake master cylinder reservoir up to the specified level.
EWA
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
Front brake caliper bracket23 Nm (2.3 m·kgf, 17 ft·lbf)
Brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf)
1
a1
New
T R..
a
b
Brake pad pin
17 Nm (1.7 m·kgf, 12 ft·lbf)
Brake hose holder nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Specified brake fluid DOT 4
T R..
T R..
1
2
b
a

FRONT BRAKE
5-22
TIP
Turn the handlebar toward right and left to
make sure that the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Adjust if necessary.
3. Pour brake fluid to the brake master cylinder reservoir up to the specified level.
EWA
WARNING
• Use only the designated brake fluid. Other brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could
cause vapor lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• Brake systemRefer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
5. Check: • Brake fluid level
The minimum level mark “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30. 6. Check:
• Brake lever free play
Refer to “ADJUSTING THE FRONT
BRAKE” on page 3-26.
• Brake lever operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
Specified brake fluid
DOT 4
a

REAR BRAKE
5-30
WARNING
• Use only the designated brake fluid. Other brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
5. Bleed:• Brake system
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
6. Check:
• Brake fluid levelThe minimum level mark “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30.
7. Check: • Brake pedal operationA softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
EAS2GC1189REMOVING THE REAR BRAKE MASTER
CYLINDER
TIP
Before removing the rear brake master cylin-
der, drain the brake fluid from the entire brake
system. 1. Remove:
• Union bolt
• Copper washers
• Brake hose
TIP
To drain any remaining brake fluid, place a con-
tainer under the master cylinder and the end of
the brake hose.
EAS2GC1190CHECKING THE REAR BRAKE MASTER
CYLINDER
1. Check:• Brake master cylinder “1”
Damage/scratches/wear  Replace.
• Brake fluid delivery passages “2” (brake master cylinder body)
Obstruction  Blow out with compressed
air.
2. Check: • Brake master cylinder kit
Damage/wear  Replace.
3. Check: • Master cylinder reservoir capCrack/damage  Replace.
• Brake master cylinder reservoir diaphragm holder
• Brake master cylinder reservoir diaphragm
Crack/damage  Replace.
4. Check: • Brake hoses
Cracks/damage/wear  Replace.
EAS2GC1191ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
EWA
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.
a
1 2

REAR BRAKE
5-32
2. Pour brake fluid to the brake fluid reservoir up to the specified level.
EWA
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
ECA
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
3. Bleed:
• Brake systemRefer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
4. Check: • Brake fluid level
The minimum level mark “a” or below 
Add.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-30. 5. Check:
• Brake pedal operation
A softy or spongy feeling  Bleed the brake
system.
Refer to “BLEEDING THE BRAKE SYS-
TEM” on page 3-25.
Specified brake fluid
DOT 4
a
a

FRONT FORK
5-42
EAS2GC1198REMOVING THE FRONT FORK LEGS
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.
TIP
Record the adjusting screw setting position be-
fore loosening the adjuster and the base valve.
2. Loosen:• Upper bracket pinch bolts
• Damper assembly
• Lower bracket pinch bolts
EWA
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
TIP
Before removing the front fork leg from the ve-
hicle, loosen the damper assembly “1” with the
cap bolt ring wrench “2”.
3. Remove:• Front fork leg (s)
EAS2GC1199DISASSEMBLING THE FRONT FORK LEGS
1. Drain:
• Fork oil
2. Remove:
• Adjuster “1”(from the inner tube)
TIP
• While compressing the inner tube “2”, set the cap bolt ring wrench “4” between the inner
tube and locknut “3”.
• Hold the locknut and remove the adjuster.
ECA
NOTICE
Do not remove the locknut as the damper
rod may go into the damper assembly and
not be taken out.
3. Remove:
• Dust seal “1”
• Oil seal clip “2”(with a flat-head screwdriver)
ECA
NOTICE
Do not scratch the inner tube.
4. Remove:
• Inner tube “1”
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a. Push in slowly “a” the inner tube just before it bottoms out and then pull it back quickly
“b”.
b. Repeat this step until the inner tube can be pulled out from the outer tube.
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench YM-01501
1 2
Cap bolt ring wrench
90890-01501
Cap bolt ring wrench YM-01501
1
23
4
1
2

FRONT FORK
5-43
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5. Remove:• Base valve “1”
(from the damper assembly)
TIP
Hold the damper assembly with the cap bolt
ring wrench “2” and use the cap bolt wrench “3”
to remove the base valve.
EAS2GC1200CHECKING THE FRONT FORK LEGS
1. Check:• Inner tube surface “a”Scratches  Repair or replace.
Use #1000 grit wet sandpaper.
Damaged oil lock piece  Replace.
• Inner tube bends Out of specification  Replace.
Use the dial gauge “1”.
TIP
The bending value is shown by one half of the
dial gauge reading.
EWA
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Check:
• Outer tubeScratches/wear/damage  Replace.
3. Measure:
• Fork spring free length “a”Out of specification  Replace.
4. Check: • Damper assembly “1”Bend/damage  Replace.
• O-ring “2” Wear/damage  Replace.
ECA
NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
Cap bolt wrench
90890-01500
Cap bolt wrench YM-01500
Cap bolt ring wrench 90890-01501
Cap bolt ring wrench YM-01501
Inner tube bending limit 0.2 mm (0.01 in)
1
2 3
Fork spring free length
470.0 mm (18.50 in)
Limit 465.0 mm (18.31 in)