2016 YAMAHA WR 450F wheel

FRONT WHEEL
5-7
3. Install:• Collar “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip.
4. Install:
• Speed sensor “1”
TIP
Apply the lithium-soap-based grease on the oil
seal lip of speed sensor.
Make sure the two projections “a” in the wheel
hub are meshed with the two slots “b” in the
speed sensor.
EAS2GC1159INSTALLING THE FRONT WHEEL
1. Install:• Front wheel
TIP
Install the brake disc “1” between the brake
pads “2” correctly. 2. Install:
• Front wheel axle “1”
TIP
Apply the lithium-soap-based grease to the
front wheel axle.
3. Tighten:
• Front wheel axle nut “1”
ECA
NOTICE
Before tightening the front wheel axle nut,
push down hard on the handlebar(s) several
times and check if the front fork rebounds
smoothly.
4. Tighten:• Front wheel axle pinch bolt “1”1
a b
LS
Front wheel axle nut
90 Nm (9.0 m·kgf, 65 ft·lbf)
Front wheel axle pinch bolt 21 Nm (2.1 m·kgf, 15 ft·lbf)
T R..
1
T R..

FRONT WHEEL
5-8
1
1

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
5-17
EAS2GC1168INTRODUCTIONEWA
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components unless absolutely necessary.
• If there is any problem with connections on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the
brake fluid, and clean it. After that, add a
suitable amount of brake fluid. Then, bleed
it after reassembly.
• Use only brake fluid for washing brake
components.
• Use new brake fluid for cleaning the brake components.
• Immediately wipe off the spilled brake fluid to avoid damage to painted surfaces or
plastic parts.
• Handle brake fluid with special care not to let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS2GC1169CHECKING THE FRONT BRAKE DISC
1. Remove: • Front wheel
Refer to “FRONT WHEEL” on page 5-4.
2. Check: • Front brake disc
Damage/galling  Replace.
3. Measure: • Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace. 4. Install:
• Front wheelRefer to “FRONT WHEEL” on page 5-4.
EAS2GC1170REMOVING THE FRONT BRAKE CALIPER
TIP
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:• Union bolt
• Copper washers
• Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid.
EAS2GC1171DISASSEMBLING THE FRONT BRAKE CAL-
IPER
1. Remove:• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seals “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening to force out the piston from the
brake caliper.
EWA
WARNING
• Cover the brake caliper piston with a rag. Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
Brake disc thickness limit 2.5 mm (0.10 in)
3
2
1

REAR BRAKE
5-27
EAS2GC1181INTRODUCTIONEWA
WARNING
If you need to disassemble the disc brake
components, observe the following precau-
tions.
• Never disassemble the brake components unless absolutely necessary.
• If there is any problem with connections on the hydraulic brake system, perform
the following jobs.
Disassemble the brake system, drain the
brake fluid, and clean it. After that, add a
suitable amount of brake fluid. Then, bleed
it after reassembly.
• Use only brake fluid for washing internal
brake components.
• Use new brake fluid for cleaning the brake components.
• Immediately wipe off the spilled brake fluid to avoid damage to painted surfaces or
plastic parts.
• Handle brake fluid with special care not to let it enter your eyes so that you may not
lost your eyesight.
• FIRST AID FOR BRAKE FLUID ENTERING THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS2GC1182CHECKING THE REAR BRAKE DISC
1. Remove: • Rear wheel
Refer to “REAR WHEEL” on page 5-9.
2. Check: • Brake disc
Damage/galling  Replace.
3. Measure: • Brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification  Replace.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 5-17.
4. Measure: • Brake disc deflection
Out of specification  Correct the brake disc
deflection or replace the brake disc. 5. Adjust:
• Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Turn the mounted position of the brake disc by one bolt hole.
c. Install the brake disc.
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:• Rear wheel
Refer to “REAR WHEEL” on page 5-9.
Brake disc thickness limit
3.5 mm (0.14 in)
Brake disc runout limit (as mea-
sured on wheel) 0.15 mm (0.0059 in)
Brake disc bolt 14 Nm (1.4 m·kgf, 10 ft·lbf)
LOCTITE®
T R..