Yamaha Wr 450 F Owners Manual

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CHAS
EC560000
STEERING
Extent of removal:1 Under bracket removal2 Bearing removal
Extent of removal Order Part name Q’ty Remarks
STEERING REMOVAL
WARNING
Support the machine securely so there is no
danger of it falling over.
Refer to “HANDLEBAR” section. Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Headlight
Handlebar
Hose guide
Front fender
1 Coupler bracket 1
2 Trip meter 1
3 Main switch 1 Disconnect the main switch lead.
4 Steering shaft cap 1
5 Steering shaft nut 1
6 Front fork 2 Refer to “FRONT FORK” section.
7 Handle crown 1
8 Ring nut 1 Use special tool.
Refer to “REMOVAL POINTS”.
9 Under bracket 1
10 Ball race cover 1
2
1
STEERING 
						

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CHASSTEERING
Extent of removal Order Part name Q’ty Remarks
11 Bearing (upper) 1
12 Bearing (lower) 1
Refer to “REMOVAL POINTS”.
13Ball race
2
2 
						

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CHAS
EC563000
REMOVAL POINTS
EC563202
Ring nut
1. Remove:
Ring nut 1 
Use the ring nut wrench 2.
WARNING
Support the steering shaft so that it may
not fall down.
Ring nut wrench:
YU-33975/90890-01403
EC563300
Bearing (lower)
1. Remove:
Bearing (lower) 1 
Use the floor chisel 2.
ACHTUNG:CAUTION:
Take care not to damage the steering shaft
thread. 
EC563400
Ball race
1. Remove:
Ball race 1 
Remove the ball race using long rod 2
and the hammer.
EC564000
INSPECTION
EC564200
Steering shaft
1. Inspect:
Steering shaft 1 
Bend/damage → Replace.
STEERING 
						

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CHASSTEERING
EC564101
Bearing and ball race
1. Wash the bearings and ball races with a
solvent.
2. Inspect:
Bearing 1 
Ball race
Pitting/damage → Replace bearings
and ball races as a set.
Install the bearing in the ball races.
Spin the bearings by hand. If the bear-
ings hang up or are not smooth in their
operation in the ball races, replace
bearings and ball races as a set.
EC565000
ASSEMBLY AND INSTALLATION
Under bracket
1. Install:
Bearing (lower) 1 
NOTE:
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference.
2. Install:
Ball race
Bearing (upper) 1 
Ball race cover 2 
NOTE:
Apply the lithium soap base grease on the
bearing and ball race cover lip.
3. Install:
Under bracket 1 
NOTE:
Apply the lithium soap base grease on the
bearing and the portion a of the steering
shaft. 
						

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CHAS
4. Install:
Plain washer 1 
Ring nut 2 
Tighten the ring nut using the ring nut
wrench 3.
Refer to “STEERING HEAD INSPEC-
TION AND ADJUSTMENT” section in
the CHAPTER 3.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
5. Check the steering shaft by turning it lock
to lock. If there is any binding, remove
the steering shaft assembly and inspect
the steering bearings.
6. Install:
Plain washer 1 
7. Install:
Front fork 1 
Handle crown 2 
Main switch 3 
Coupler bracket 4 
Hose guide bracket 5 
NOTE:
Install the coupler bracket on the outside of
the hose guide bracket.
Temporarily tighten the pinch bolts (under
bracket).
Do not tighten the pinch bolts (handle crown)
yet.
8. Install:
Plain washer 1 
Steering shaft nut 2 
T R..145 Nm (14.5 m · kg, 105 ft · lb)
STEERING 
						

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CHASSTEERING
9. Install:
Steering shaft cap 1 
10. After tightening the nut, check the steer-
ing for smooth movement. If not, adjust
the steering by loosening the ring nut little
by little.
11. Adjust:
Front fork top end a 
Front fork top end (standard) a:
Zero mm (Zero in)
12. 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.
13. Install:
Trip meter 1 
Bolt (trip meter) 2 
NOTE:
Install the trip meter over the coupler bracket
3.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..7 Nm (0.7 m · kg, 5.1 ft · lb) 
						

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CHASSWINGARM
EC570000
SWINGARM
Extent of removal:1 Swingarm removal
Extent of removal Order Part name Q’ty Remarks
SWINGARM REMOVAL
WARNING
Support the machine securely so there is no
danger of it falling over.
Preparation for removal Hold the machine by placing the
suitable stand under the engine.
Brake hose holder
Rear caliper
Bolt (brake pedal)
Drive chainRefer to “FRONT BRAKE AND REAR
BRAKE” section.
Shift the brake pedal backward.
1 Chain support 1
2 Chain tensioner (lower) 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
1 
						

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CHASSWINGARM
EC578000
SWINGARM DISASSEMBLY
Extent of removal:1 Swingarm disassembly2 Connecting rod removal and disassembly
3 Relay arm removal and disassembly
Extent of removal Order Part name Q’ty Remarks
SWINGARM DISASSEMBLY
1 Cap 2
2 Relay arm 1
3 Connecting rod 1
4 Collar 2
5 Oil seal 2
6 Thrust bearing 2
7 Bush 2
8 Oil seal 8
9 Bearing 8 Refer to “REMOVAL POINTS”.
1
2
32
3 
						

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CHASSWINGARM
EC573000
REMOVAL POINTS
EC573200
Bearing
1. Remove:
Bearing 1 
NOTE:
Install the bearing by pressing its outer race.
EC574010
INSPECTION
Wash the bearings, bushes, collars, and cov-
ers in a solvent.
EC574111
Swingarm
1. Inspect:
Bearing 1 
Bush 2 
Free play exists/unsmooth revolution/
rust → Replace bearing and bush as a
set.
2. Inspect:
Oil seal 3 
Damage → Replace.
EC574210
Relay arm
1. Inspect:
Bearing (polylube bearing) 1 
Collar 2 
Free play exists/unsmooth revolution/rust
→ Replace bearing and collar as a set.
2. Inspect:
Bearing (polylube bearing) 1
Loss of solid lubrication → Replace.
Oil seal 3 
Damage → Replace.
NOTE:
Polylube bearings, with solid lubrication, have
been adopted with the intent to make the nee-
dle bearings, used in this model, maintenance
free. With polylube bearings, no grease nipple
and regular lubrication is necessary. However,
grease should be applied to all oil seals and
collars when removed or installed. 
						

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CHASSWINGARM
EC574310
Connecting rod
1. Inspect:
Bearing (polylube bearing) 1
Collar 2 
Free play exists/unsmooth revolution/rust
→ Replace bearing and collar as a set.
2. Inspect:
Bearing (polylube bearing) 1
Loss of solid lubrication → Replace.
Oil seal 3 
Damage → Replace.
NOTE:
Polylube bearings, with solid lubrication, have
been adopted with the intent to make the nee-
dle bearings, used in this model, maintenance
free. With polylube bearings, no grease nipple
and regular lubrication is necessary. However,
grease should be applied to all oil seals and
collars when removed or installed.
EC575000
ASSEMBLY AND INSTALLATION
EC575201
Bearing and oil seal
1. Install:
Bearing 1 
Oil seal 2 
To swingarm.
NOTE:
Apply the molybdenum disulfide grease on
the bearing when installing.
Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
First install the outer and then the inner bear-
ings to a specified depth from inside.
Installed depth of bearings:
Outer a: Zero mm (Zero in)
Inner b: 8.5 mm (0.33 in)