Yamaha Wr 450 F Owners Manual

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CHASFRONT FORK
19. Wait ten minutes until the air bubbles
have been removed from the front fork,
and the oil has dispense evenly in system
before setting recommended oil level.
NOTE:
Fill with the fork oil up to the top end of the
outer tube, or the fork oil will not spread over to
every part of the front forks, thus making it
impossible to obtain the correct level.
Be sure to fill with the fork oil up to the top of
the outer tube and bleed the front forks.
20. Measure:
Oil level (left and right) a 
Out of specification → Adjust.
NOTE:
Be sure to install the spring guide 2 when
checking the oil level.
WARNING
Never fail to make the oil level adjustment
between the maximum and minimum level
and always adjust each front fork to the
same setting. Uneven adjustment can
cause poor handling and loss of stability.
Standard oil level:
130 mm (5.12 in)
Extent of adjustment:
80 ~ 150 mm (3.15 ~ 5.91 in)
From top of outer tube with
inner tube and damper rod 1
fully compressed without
spring. 
						

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CHASFRONT FORK
21. Measure:
Distance a 
Out of specification → Turn into the
locknut.
Distance a:
20 mm (0.79 in) or more
Between damper rod 1 top and
locknut 2 top.
22. Loosen:
Rebound damping adjuster 1 
NOTE:
Loosen the rebound damping adjuster finger
tight.
Record the set position of the adjuster (the
amount of turning out the fully turned in posi-
tion).
23. Install
Cushion rubber 1 
Washer 2 
Spacer 3 
To cap bolt 4.
NOTE:
Install the cushion rubber with its smaller
dia.end a facing the cap bolt.
24. Install:
Push rod 1 
Fork spring 2 
NOTE:
Install the fork spring with the damper rod 3
pulled up.
After installing the fork spring, hold the
damper rod end so that it will not go down.
25. Install:
Cap bolt 1 
Fully tighten the cap bolt onto the
damper rod by hand. 
						

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CHASFRONT FORK
26. Tighten:
Cap bolt (locknut) 1 
NOTE:
While compressing the fork spring, set the
thin type spanners 2 between the spacer 3
and spring guide 4.
Hold the locknut 5 and tighten the cap bolt
with specified torque.
27. Install:
Cap bolt 1 
To outer tube.
NOTE:
Temporarily tighten the cap bolt.
T R..29 Nm (2.9 m · kg, 21 ft · lb)
28. Install:
Protector guide 1 
Installation
1. Install:
Front fork 1 
NOTE:
Temporarily tighten the pinch bolts (under
bracket).
Do not tighten the pinch bolts (handle crown)
yet.
2. Tighten:
Cap bolt 1 
3. Adjust:
Front fork top end a 
Front fork top end (standard) a:
Zero mm (Zero in)
T R..30 Nm (3.0 m · kg, 22 ft · lb) 
						

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CHASFRONT FORK
4. Tighten:
Pinch bolt (handle crown) 1 
Pinch bolt (under bracket) 2 
ACHTUNG:CAUTION:
Tighten the under bracket to specified
torque. If torqued too much, it may cause
the front fork to malfunction.
5. Install:
Brake hose holder 1 
Caliper 2 
Bolt (caliper) 3 
NOTE:
Fit the brake hose holder cut a over the pro-
jection b on the front fork and clamp the brake
hose.
6. Install:
Brake hose holder 1 
Bolt (brake hose holder) 2 
Protector 3 
Bolt (protector) 4 
NOTE:
When installing the brake hose holder, align
the top a of the brake hose neck with the
brake hose holder bottom b. Then pass the
brake hose 5 in front of the axle boss c and
fit it into the hose groove d so that the brake
hose does not contact the nut (wheel axle).
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
7. Adjust:
Rebound damping force
NOTE:
Turn in the damping adjuster 1 finger-tight
and then turn out to the originally set position. 
						

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CHAS
EC5B0000
HANDLEBAR
Extent of removal:1 Handlebar removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removalHANDLEBAR REMOVAL
Headlight
1 Hot starter cable  1 Disconnect at the lever side.
2 Hot starter lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1 Disconnect the clutch switch lead.
5“ENGINE STOP” button 1 Disconnect  the “ENGINE STOP” button
lead.
6 Lights switch 1
7 Master cylinder 1 Refer to “REMOVAL POINTS”.
8 Start switch 1 Disconnect the start switch lead.
9 Throttle cable cap 1
10 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
11 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
12 Grip (right) 1 Refer to “REMOVAL POINTS”.
13 Tube guide 1
14 Cover (grip cap) 1
15 Grip (left) 1 Refer to “REMOVAL POINTS”.
16 Handlebar holder (upper) 2
17 Handlebar 1
1
HANDLEBAR 
						

							 
5 - 41
CHAS
 
EC5B3000 
REMOVAL POINTS 
EC5B3100 
Master cylinder  
1. Remove: 
 
Master cylinder bracket   
1  
  
 
Master cylinder   
2  
 
ACHTUNG:CAUTION:
 
 
Do not let the master cylinder hang on the
brake hose. 
 
Keep the master cylinder cap side hori- 
zontal to prevent air from coming in. 
EC5B3200 
Grip  
1. Remove: 
 
Grip   
1  
 
NOTE:
 
Blow in air between the handlebar or tube
guide and the grip. Then remove the grip 
which has become loose. 
EC5B4000 
INSPECTION 
EC5B4100 
Handlebar  
1. Inspect: 
 
Handlebar   
1  
 
Bends/cracks/damage   
→  
 Replace.
WARNING
 
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the 
handlebar. 
HANDLEBAR 
						

							 
5 - 42
CHAS
 
HANDLEBAR 
EC5B5000 
ASSEMBLY AND INSTALLATION
Handlebar  
1. Install: 
 
Handlebar   
1  
  
 
Handlebar holder   
2  
  
 
Bolt (handlebar holder)   
3  
 
NOTE:
 
 
The handlebar holder should be installed
with the punched mark   
a  
 forward. 
 
First tighten the bolts on the front side of the
handlebar holder, and then tighten the bolts 
on the rear side.
2. Install: 
 
Grip (left)   
1  
 
Apply the adhesive to the handlebar   
2  
.
NOTE:
 
 
Before applying the adhesive, wipe off
grease or oil on the handlebar surface   
a  
with a lacquer thinner. 
 
Install the grip (left) to the handlebar so that
the line   
b  
 between the two arrow marks 
faces straight upward.
T R..28 Nm (2.8 m · kg, 20 ft · lb)
 
3. Install: 
 
Grip (right)   
1  
  
 
Collar  
2  
 
Apply the adhesive on the tube guide 
3 
.
NOTE:
 
 
Before applying the adhesive, wipe off
grease or oil on the tube guide surface  
a  
with a lacquer thinner. 
 
Install the grip to the tube guide so that the
grip match mark  
b  
 and tube guide slot   
c 
form the angle as shown.
R
L
90˚
3 1b
c 
						

							 
5 - 43
CHAS
 
HANDLEBAR 
4. Install: 
 
Cover (grip cap)  
1 
 
Throttle grip  
2
NOTE:
 
Apply the lithium soap base grease on the 
throttle grip sliding surface. 
5. Install: 
 
Throttle cables  
1 
 
To tube guide  
2 
.
NOTE:
 
Apply the lithium soap base grease on the
throttle cable end and tube guide cable wind- 
ing portion. 
6. Install: 
 
Throttle cable cap  
1 
  
 
Screw (throttle cable cap)  
2 
 
WARNING
 
After tightening the screws, check that the
throttle grip  
3 
 moves smoothly. If it does 
not, retighten the bolts for adjustment.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
7. Install:
Cover (grip cap) 1 
Cover (throttle cable cap) 2  
						

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CHASHANDLEBAR
8. Install:
Start switch 1 
Master cylinder 2 
Master cylinder bracket 3 
Bolt (master cylinder bracket) 4 
Clamp 5 
NOTE:
The start switch and master cylinder bracket
should be installed according to the dimen-
sions shown.
Install the bracket so that the arrow mark a
faces upward.
First tighten the bolt on the upper side of the
master cylinder bracket, and then tighten the
bolt on the lower side.
T R..9 Nm (0.9 m · kg, 6.5 ft · lb)
Zero mm
(Zero in)Zero mm
(Zero in)
9. Install:
Lights switch 1
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
10. Install:
“ENGINE STOP” button 1 
Clutch lever holder 2 
Bolt (clutch lever holder) 3 
Hot starter lever holder 4
Bolt (hot starter lever holder) 5
Clamp 6 
NOTE:
The “ENGINE STOP” button, clutch lever
holder and clamp should be installed accord-
ing to the dimensions shown.
Pass the “ENGINE STOP” button lead in the
middle of the clutch lever holder.
T R..4 Nm (0.4 m · kg, 2.9 ft · lb)
T R..4 Nm (0.4 m · kg, 2.9 ft · lb) 
						

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CHASHANDLEBAR
11. Install:
Clutch cable 1 
Hot starter cable 2
NOTE:
Apply the lithium soap base grease on the
clutch cable end and hot starter cable end.
12. Adjust:
Clutch lever free play
Refer to “CLUTCH ADJUSTMENT”
section in the CHAPTER 3.
Hot starter lever free play
Refer to “HOT STARTER LEVER
ADJUSTMENT” section in the CHAP-
TER 3.
13. Fasten the hot starter cable 1 and clutch
cable 2 with a clamp 3.
1
2
3
14. Insert the end of the fuel breather hose
1 into the hole in the steering shaft cap
2.
1
2