2016 YAMAHA WR 450F wheel bolts

MAINTENANCE AFTER BREAK-IN
1-31
EAS2GC1055
MAINTENANCE AFTER BREAK-IN
After a break-in, perform careful maintenance
to get ready for the next practice or race.
Refer to “PRE-OPERATION INSPECTION
AND MAINTENANCE” on page 3-9.
EAS2GC1056MAJOR MAINTENANCE
1. For the engine• Leaks around the engineCheck for pressure l eaks from the cylinder
head or the cylinder, oil leaks from the
crankcase or the case cover, leaks from the
coolant system, and other leaks.
• Check that the valve, the cylinder head, the cylinder, the piston, and the piston ring fit
one another, and that contact between the
valve and the cylinder head, and that be-
tween the cylinder and the piston are cor-
rect.
• Engine oil change Drain the oil, and check for dirt and foreign
materials such as metal chips. (If any foreign
material is mixed, disassemble and check
the crankcase.)
Pour the specified amount of the recom-
mended oil.
• AC magneto
Check for looseness in mounted areas of
the rotor and the stator.
Check that the connector is not being dis-
connected.
• Silencer Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel (s) Check the wheel for runout. Check the
spoke for looseness.
• Brake(s) Check the brake disc mounting bolt for
looseness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks. • Cable
Grease and adjust cables.
•Drive chain
Lubricate the drive chain and adjust its ten-
sion.
• Fuel tank
Clean the inside of the fuel tank. Check for
leaks.
• Suspension
Check for oil leaks in the front fork or the rear
shock absorber. Check that the mounted
conditions are good.
• Sprocket Check for looseness in the sprocket mount-
ed on the rear wheel.
• Mounting bolts and nuts
Check mounted areas for looseness.
ECA
NOTICE
After a break-in or before each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them. (Refer to “TORQUE-CHECK
POINTS” on page 1-32.)
• Greasing and oilingAlways grease or oil the specified points.

PRE-OPERATION INSPECTION AND MAINTENANCE
3-9
EAS2GC1079
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAS2GC1080GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
Coolant Check that coolant is filled up to the radiator cap.
Check the cooling system for leakage. 3-10 – 12
Fuel Check that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage. 1-28
Engine oil Check that the oil level is correct. Check the crank-
case and oil line for leakage. 3-16 – 18
Gear shifter and clutch Check that gears can be shifted correctly in order and
that the clutch operates smoothly. 3-12 – 13
Throttle grip/Housing Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary. 3-13 – 14
Brakes Check the play of front brake and effect of front and
rear brake. 3-25 – 31
Drive chain Check drive chain slack and alignment. Check that
the drive chain is lubricated properly. 3-31
5-69 – 70
Wheels Check for excessive wear and tire pressure. Check
for loose spokes and have no excessive play. 3-36 – 37
Steering Check that the handlebar can be turned smoothly and
have no excessive play. 3-37 – 38
Front forks and rear
shock absorber Check that they operate smoothly and there is no oil
leakage.
3-31 – 36
Cables (wires) Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.
—
Exhaust pipe Check that the exhaust pipe is tightly mounted and
has no cracks. 3-15 – 16
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is
not loose. 5-10 – 11
Lubrication Check for smooth operation. Lubricate if necessary. 3-14
3-38 – 39
Bolts and nuts Check the chassis and engine for loose bolts and
nuts. 1-32 – 33
Lead connectors Check that the AC magneto, ECU and ignition coil are
connected tightly. 1-9 – 12
Settings Is the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?
4-1 – 8

FRONT WHEEL
5-6
EAS2GC1157DISASSEMBLING THE FRONT WHEEL
1. Remove:• Oil seals
• Bearings
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a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flat-head screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel sur-
face.
c. Remove the bearings with a bearing puller.
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EAS2GC1158ASSEMBLING THE FRONT WHEEL
1. Install:• Bearing (left side) “1”
• Spacer “2”
• Bearing (right side) “3”
• Oil seal “4”
TIP
• Apply the lithium-soap-based grease to the bearing and the oil seal lip when installing.
• Left 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.
1 2
New
Brake disc bolt
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
LOCTITE®
3
2
14
New
1
T R..

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 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
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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.
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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..

FRONT FORK
5-40
EAS2GC1197
FRONT FORK
Removing the front fork legs
OrderPart name Q’tyRemarks
Use a suitable stand to raise the front wheel
off the ground.
Front wheel Refer to “FRONT WHEEL” on page 5-4.
Front brake caliper Refer to “FRONT BRAKE” on page 5-13.
1 Brake hose holder 2
2 Protector 1
3 Upper bracket pinch bolts 2 Loosen.
4 Damper assembly 1 Loosen.
5 Lower bracket pinch bolts 2 Loosen.
6 Front fork leg 1
7 Reflector/Stay/Nut 1 For Canada
For installation, reverse the removal proce-
dure.

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