2016 YAMAHA WR 450F air suspension

CHASSIS SPECIFICATIONS
2-9
Rear suspensionType Swingarm (link suspension)
Spring/shock absorber type Coil spring/Gas-hydraulic damper
Rear shock absorber assembly travel 126.0 mm (4.96 in)
Spring free length 275.0 mm (10.83 in)
Spring installed length 263.0 mm (10.35 in)
Spring rate K1 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in)
Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)
Optional spring available Yes
Enclosed gas/air pressure (STD) 980 kPa (9.8 kgf/cm
2, 139.4 psi)
Spring preload adjusting positions
Minimum Position in which the spring is turned in 1.5 mm
(0.06 in) from its free length.
Standard Position in which the spring is turned in 12 mm
(0.47 in) from its free length.
Maximum Position in which the spring is turned in 18 mm
(0.71 in) from its free length.
Rebound damping adjusting positions Minimum 30 clicks out*
Standard 14 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in
Compression damping setting
(for fast compression damping)Minimum 2 turns out*
Standard 1-3/4 turns out*
Maximum Fully turned in
* With the adjuster fully turned in
Compression damping setting
(for slow compression damping)Minimum 20 clicks out*
Standard 10 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in
Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in)
Drive chainSize/manufacturer DID520VM2/DAIDO
Number of links 114
Drive chain slack (on a suitable stand) 50.0–60.0 mm (1.97–2.36 in)
15-link length limit 239.3 mm (9.42 in)

3
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE............................................................................. 3-1
INTRODUCTION ........................................................................................ 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION
CONTROL SYSTEM ....................... .......................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 3-2
MAINTENANCE INTERVALS FOR COMPETITION USE ......................... 3-4
PRE-OPERATION INSPECTION AND MAINTENANCE ................................. 3-9
GENERAL INSPECTION AND MAINTENANCE........................................ 3-9
ENGINE .......................................................................................................... 3-10
CHECKING THE COOLANT LEVEL ........................................................ 3-10
CHECKING THE COOLING SYSTEM ..................................................... 3-10
CHANGING THE COOLANT.................................................................... 3-10
CHECKING THE RADIATOR CAP .......................................................... 3-11
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ....... 3-11
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-12
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-13
LUBRICATING THE THROTTLE CABLE ................................................ 3-14
CLEANING THE AIR FILTER ELEMENT................................................. 3-14
CHECKING THE THROTTLE BODY JOINT ............................................ 3-15
CHECKING THE BREATHER HOSES .................................................... 3-15
CHECKING THE EXHAUST SYSTEM............................. ........................ 3-15
CHECKING THE FUEL LINE ................................................................... 3-16
CHECKING THE ENGINE OIL LEVEL............................. ........................ 3-16
CHANGING THE ENGINE OIL ................................................................ 3-17
ADJUSTING THE ENGINE IDLING SPEED ......... ................................... 3-19
ADJUSTING THE VALVE CLEARANCE ................................................. 3-20
CLEANING THE SPARK ARRESTER ..................................................... 3-24
CHASSIS ........................................................................................................ 3-25
BLEEDING THE BRAKE SYST EM .......................................................... 3-25
CHECKING THE BRAKE HOSE .............................................................. 3-26
ADJUSTING THE FRONT BRAKE .......................................................... 3-26
ADJUSTING THE REAR BRAKE ............................................................. 3-27
CHECKING THE FRONT BR AKE PADS ................................................. 3-27
CHECKING THE REAR BRAKE PADS ........................... ........................ 3-29
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-30
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-30
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-31
CHECKING THE FRONT FORK LEGS ................................................... 3-31
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-32
CLEANING THE FRONT FORK OI L SEAL AND DUST SEAL ................ 3-32
AIR BLEEDING FROM FRONT FORK .................................................... 3-32
ADJUSTING THE FRONT FORK LEGS .................................................. 3-33
CHECKING THE SWINGARM OPERATION ........................................... 3-34
CHECKING THE REAR SUSPENSION ................................................... 3-34

CHASSIS
3-33
3. Tighten:• Air bleed screw
EAS2GC1115ADJUSTING THE FRONT FORK LEGSEWA
WARNING
• Always adjust the left and right front forks evenly. If this is not done, the vehicle may
have poor stability.
• Securely support the vehicle so that there
is no danger of it falling over.
Rebound damping
ECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust: • Rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
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Compression dampingECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:• Compression damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or “b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Air bleed screw1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Direction “a” Rebound damping is increased (sus-
pension is harder).
Direction “b” Rebound damping is decreased (sus-
pension is softer).
Rebound damping adjusting posi-
tionsMaximumFully turned in
Standard 11 clicks out*
Minimum 20 clicks out*
* With the adjuster fully turned in
T R..
1
Direction “a” Compression damping is increased
(suspension is harder).
Direction “b” Compression damping is decreased
(suspension is softer).
Compression damping adjusting
positions Maximum Fully turned in
Standard 13 clicks out*
Minimum 20 clicks out*
* With the adjuster fully turned in
1
a b
ab
1

CHASSIS
3-36
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Compression damping (for slow compres-
sion damping)
ECA
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:• Compression damping (for slow compres-
sion damping)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster “1” in the direction of “a” or “b” to make an adjustment.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS2GC1119CHECKING THE TIRES
1. Measure:
• Tire pressureOut of specification  Regulate.
TIP
• Check the tire while it is cold.
• Loose bead stoppers allow the tire to slip off
its position on the rim when the tire pressure
is low.
• If the tire valve stem is found tilted, the tire is
considered to be slipping off its position. Cor-
rect the tire position.
EAS2GC1120CHECKING AND TIGHTENING THE
SPOKES
1. Check:• SpokesBend/damage  Replace.
Loose  Tighten.
TIP
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
Direction “a”
Compression damping is increased
(suspension is harder).
Direction “b” Compression damping is decreased
(suspension is softer).
Compression damping setting
(for slow compression damping)MaximumFully turned in
Standard 10 clicks out*
Minimum 20 clicks out*
* With the adjuster fully turned in
1 a
b
1
ba
Tire air pressure (measured on cold
tires)
Front 100 kPa (1.00 kgf/cm
2, 15 psi)
Rear 100 kPa (1.00 kgf/cm
2, 15 psi)

CHASSIS
4-2
• Under a stony or a hard road condition, the tire pressure should be hi gher to prevent a flat
tire.
EAS2GC1140FRONT FORK SETTING
The front fork setting should be made depend-
ing on the rider’s feeli ng of an actual run and
the circuit conditions.
The front fork setting includes the following
three factors:
1. Setting of air spring characteristics • Change the fork oil amount.
2. Setting of spring preload • Change the spring.
3. Setting of damping force
• Change the compression damping force.
• Change the rebound damping force.The spring acts on the load and the damping
force acts on the cushion travel speed.
EAS2GC1141CHANGE IN AMOUNT AND CHARACTERIS-
TICS OF FORK OIL
Damping characteristic near the final stroke
can be changed by changing the fork oil
amount.
EWA
WARNING
Adjust the oil amount in 5 cm3 (0.2 US oz,
0.2 Imp.oz) increments or decrements. Too
small oil amount causes the front fork to
produce a noise at full rebound or the rider
to feel some pressure on his hands or body.
Alternatively, too large oil amount will
cause the air spring characteristics to have
a tendency to be stiffer with the consequent
deteriorated performance and characteris-
tics. Therefore, adjust the front fork within
the specified range.
EAS2GC1142SETTING OF SPRING AFTER REPLACE-
MENT
As the front fork setting can be easily affected
by the rear suspension, take care so that the
front and the rear are balanced (in position etc.)
when setting the front fork.
1. Use of soft spring
• Change the rebound damping force.Turn out one or two clicks.
• Change the compression damping force.
Turn in one or two clicks.
TIP
Generally a soft spring gives a soft riding feel-
ing. Rebound damping tends to become stron-
ger and the front fork may sink deeply over a
series of gaps.
2. Use of stiff spring• Change the rebound damping force.
Turn in one or two clicks.
• Change the compression damping force. Turn out one or two clicks.
Extent of adjustment
100–120 kPa (1.00–1.20 kgf/cm
2,
15–18 psi)
Standard oil amount 345 cm
3 (11.66 US oz, 12.14
lmp.oz)
Extent of adjustment 300–365 cm
3 (10.14–12.34 US
oz, 10.58–12.87 Imp.oz)
A. Air spring characteristics in relation to oil amount change
B. Load
C. Stroke
1. Max. oil amount
2. Standard oil amount
3. Min. oil amount

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