2016 YAMAHA WR 450F warning

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

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”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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)

FRONT FORK
5-44
5. Check:• Base valve “1”
Wear/damage  Replace.
Contamination  Clean.
• O-rings “2”
Wear/damage  Replace.
• Base valve bushing “3” Wear/damage  Replace.
• Spring “4” Damage/fatigue  Replace the base valve.
• Air bleed screw “5”
Wear/damage  Replace.
6. Check: • Contacting surface “a”Wear/damage  Replace.
7. Check: • Adjuster “1”
• O-rings “2”
Wear/damage  Replace.EAS2GC1201ASSEMBLING THE FRONT FORK LEGSEWA
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to replace the following parts:
• Inner tube bushing
• Outer tube bushing
• Oil seals
• Copper washers
• Before assembling the front fork leg, make
sure that all of the components are clean.
1. Stretch the damper assembly fully.
2. Fill: • Damper assembly
ECA
NOTICE
• Be sure to use the recommended oil. Other
oils may have an adverse effect on front
fork performance.
• When disassembling and assembling the front fork leg, take care not to allow any
foreign material to enter the front fork.
3. After filling, pump the damper assembly “1” slowly up and down (about 200 mm (7.9 in)
stroke) several times to bleed the damper
assembly of air.
TIP
Avoid excessive full stroke. A stroke of 200 mm
(7.9 in) or more will cause air to enter. In this
case, repeat the steps 1 to 3.
2 1
New
New
New
2
2 1
5 4 3
a
New
Recommended oil
Yamaha Suspension Oil S1
Standard oil amount 210 cm
3 (7.10 US oz, 7.39
Imp.oz)
New
1
2

FRONT FORK
5-51
2. Tighten:• Damper assembly “1”
TIP
Use the cap bolt ring wrench “2” to tighten the
damper assembly.
3. Adjust:
• Front fork top end “a” 4. 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.
5. Install:• Speed sensor lead “1”
• Plate 1 “2”(to the right front fork protector)
TIP
Install the speed sensor lead so that its paint “a”
directs as shown and align the bottom “b” of the
plate 1 with the same paint.
Damper assembly
30 Nm (3.0 m·kgf, 22 ft·lbf)
Cap bolt ring wrench 90890-01501
Cap bolt ring wrench YM-01501
Front fork top end (standard) “a” 5 mm (0.20 in)
T R..
2
1
a
Upper bracket pinch bolts21 Nm (2.1 m·kgf, 15 ft·lbf)
Lower bracket pinch bolts 21 Nm (2.1 m·kgf, 15 ft·lbf)
Plate 1 bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T R..
T R..
2 1
T R..
1
2
a
b

STEERING HEAD
5-55
EAS2GC1204REMOVING THE LOWER BRACKET
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.
2. Remove:• Rng nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.
EWA
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS2GC1205CHECKING THE STEERING HEAD
1. Wash with kerosene:• Bearing
• Bearing races
2. Check: • Bearing
• Bearing races
Damage/pitting  Replace.
3. Replace:
• Bearing
• Bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing race from the steering head pipe with a long rod “1” and a hammer.
b. Remove the bearing race from the lower bracket with a chisel “2” and a hammer.
c. Install a new bearing race.
ECA
NOTICE
If the bearing race is not installed properly,
the steering head pipe could be damaged.
TIP
Always replace the bearing and the bearing
race as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check: • Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAS2GC1206INSTALLING THE STEERING HEAD
1. Install:
• Lower bearing “1”
TIP
Apply the lithium-soap-based grease on the
dust seal lip and bearing inner circumference.
2. Install:• Bearing races
• Upper bearing “1”
• Bearing race cover “2”
Steering nut wrench
90890-01403
Exhaust flange nut wrench YU-A9472

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
5-61
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