2016 YAMAHA YZ450F boot

EASB111005
SAFETY INFORMATION
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road
use on public lands may also be illegal. Please check local regulations before riding.
• THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at maximum power until you are totally familiar with its char-
acteristics.
• THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this machine.
• ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an approved helmet with goggles or a face shield. Also
wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not
be caught in any of the moving parts or controls of the machine.
• ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the pre-oper-
ation checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or ex-
haust system. Never refuel in the vicinity of an open flame, or while smoking.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get
into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, imme-
diately wash skin areas with soap and water, and change your clothes.
• ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are
poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Car-
bon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.
Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope
or soft ground as it may fall over.
• THE ENGINE, EXHAUST PIPE AND MUFFLER WILL BE VERY HOT AFTER THE ENGINE HAS
BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
For safety, drain the gasoline from the fuel tank before transporting the vehicle.

LUBRICATION POINTS AND LUBRICANT TYPES
2-22
Front brake caliper dust seal
Front brake caliper piston outer surface
Front brake caliper pin bolt and boot
Front brake master cylinder push rod end
Front brake master cylinder kit
Rear brake caliper piston
Rear brake caliper piston seal
Rear brake caliper dust seal
Rear brake caliper piston outer surface
Rear brake caliper pin bolt and boot
Rear brake master cylinder push rod end
Rear brake master cylinder kitLubrication point Lubricant typesS
S
S
S
S
S
S

FRONT BRAKE
4-15
Disassembling the front brake master cylinder
Order Part name Q’ty Remarks
1 Push rod 1
2 Dust boot 1
3 Circlip 1
4Washer 1
5 Brake master cylinder kit 1
For assembly, reverse the disassemble pro-
cedure.
BF
5
4
3
2
1
S
New
New

FRONT BRAKE
4-20
3. Install:
• Spring “1”
Install to the brake master cylinder piston
“2”.
TIP
Install the spring with a smaller inside diameter
to the brake master cylinder piston.
4. Install:
• Brake master cylinder kit “1”
• Washer “2”
• Circlip “3”
• Dust boot “4”
• Push rod “5”
TIP
• Before installation, apply brake fluid to the
brake master cylinder kit.
• Before installation, apply silicone grease to
the push rod end.
• Use circlip pliers to install the circlip.
EASB111146INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder “1”
TIP
• Install the front brake master cylinder holder
with the “UP” mark facing up.
• First, tighten the upper bolt, then the lower
bolt.
2. Install:
• Copper washers
• Brake hose
• Union bolt
EWA13530
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA1DX1007
NOTICE
During installation, bring the brake hose
into contact with the brake master cylinder
projection “a” and make its bent portion “b”
face downward.
12
3
2 1
3
New
New
Brake master cylinder holder bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
T R..
New
T R..

REAR BRAKE
4-25
Disassembling the rear brake master cylinder
Order Part name Q’ty Remarks
1 Dust boot 1
2 Circlip 1
3 Push rod 1
4 Brake master cylinder kit 1
For assembly, reverse the disassemble pro-
cedure.
4
3
2
1
BF
S
New
New

REAR BRAKE
4-30
EASB111158ASSEMBLING 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.
1. Wash the brake master cylinder and the
brake master cylinder kit with brake fluid.
2. Install:
• Primary cylinder cup “1”
• Secondary cylinder cup “2”
Install to the brake master cylinder piston
“3”.
EWA
WARNING
Apply brake fluid to the cylinder cups and
install them as shown. Wrong orientation in
installation causes poor braking perfor-
mance.
3. Install:
• Spring “1”
Install to the brake master cylinder piston
“2”.
TIP
Install the spring with a smaller inside diameter
to the brake master cylinder piston.4. Install:
• Master cylinder kit “1”
• Push rod “2”
• Circlip “3”
• Dust boot “4”
TIP
• Before installation, apply brake fluid to the
brake master cylinder kit.
• Before installation, apply silicone grease to
the push rod end.
• Use circlip pliers to install the circlip.
EASB111159INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• 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 of the brake
hose touches the projection “a” on the
brake caliper. Specified brake fluid
DOT 4
2
3
1
2
3
1Brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
12
New
New
13
4
2NewNew
New
T R..