2006-2009 Yamaha YZ450F owner´s service manual

Table of Contents

General Information

1. Description
   • Overview of the YZ450F model
   • 1-1
2. Machine Identification
   • Identification number locations
   • 1-2
3. Important Information
   • Precautions and important notices
   • 1-3
4. Checking of Connection
   • Inspecting electrical and mechanical connections
   • 1-6
5. Special Tools
   • List and usage of special tools
   • 1-7
6. Control Functions
   • Detailed description of control functions
   • 1-10
7. Fuel
   • Fuel requirements and refueling instructions
   • 1-13
8. Starting and Break-In
   • Procedures for starting and breaking in a new engine
   • 1-14
9. Torque-Check Points
   • Locations and specifications for torque checks
   • 1-18
10. Cleaning and Storage
    • Cleaning procedures and storage guidelines
    • 1-19

Specifications

1. General Specifications
   • Overall dimensions, weight, and capacities
   • 2-1
2. Maintenance Specifications
   • Detailed maintenance requirements
   • 2-4
3. General Torque Specifications
   • Torque values for various components
   • 2-18
4. Definition of Units
   • Explanation of units used in the manual
   • 2-18
5. Lubrication Diagrams
   • Lubrication points and types of lubricants
   • 2-19
6. Cable Routing Diagram
   • Diagrams showing proper cable routing
   • 2-21

Regular Inspection and Adjustments

1. Maintenance Intervals
   • Schedule of regular maintenance tasks
   • 3-1
2. Pre-Operation Inspection and Maintenance
   • Checklist for pre-operation inspection
   • 3-4
3. Engine
   • Engine maintenance and inspection procedures
   • Air filter, spark plug, valve clearance
   • 3-5
4. Chassis
   • Chassis inspection and adjustment procedures
   • Suspension, brakes, wheels
   • 3-24
5. Electrical
   • Electrical system inspection and maintenance
   • Battery, lights, switches
   • 3-46

Engine

1. Seat, Fuel Tank and Side Covers
   • Removal and installation procedures
   • 4-1
2. Exhaust Pipe and Silencer
   • Removal, inspection, and installation
   • 4-3
3. Radiator
   • Inspection, maintenance, and replacement
   • 4-6
4. Carburetor
   • Disassembly, inspection, and reassembly
   • 4-9
5. Camshafts
   • Removal, inspection, and installation
   • 4-22
6. Cylinder Head
   • Removal, inspection, and installation
   • 4-30
7. Valves and Valve Springs
   • Inspection and replacement procedures
   • 4-34
8. Cylinder and Piston
   • Removal, inspection, and installation
   • 4-43
9. Clutch
   • Disassembly, inspection, and reassembly
   • 4-49
10. Oil Filter, Water Pump and Crankcase Cover (Right)
    • Removal, inspection, and installation
    • 4-56
11. Balancer
    • Inspection and maintenance
    • 4-63
12. Oil Pump
    • Inspection and maintenance
    • 4-66
13. Kick Axle and Shift Shaft
    • Inspection and maintenance
    • 4-70
14. CDI Magneto
    • Inspection and replacement
    • 4-78
15. Engine Removal
    • Procedures for engine removal
    • 4-81
16. Crankcase and Crankshaft
    • Disassembly, inspection, and reassembly
    • 4-86
17. Transmission, Shift Cam and Shift Fork
    • Inspection and maintenance
    • 4-95

Chassis

1. Front Wheel and Rear Wheel
   • Removal, inspection, and installation
   • 5-1
2. Front Brake and Rear Brake
   • Inspection, maintenance, and replacement
   • 5-10
3. Front Fork
   • Disassembly, inspection, and reassembly
   • 5-26
4. Handlebar
   • Inspection, adjustment, and replacement
   • 5-43
5. Steering
   • Inspection, adjustment, and replacement
   • 5-49
6. Swingarm
   • Inspection, maintenance, and replacement
   • 5-54
7. Rear Shock Absorber
   • Disassembly, inspection, and reassembly
   • 5-62

Electrical

1. Electrical Components and Wiring Diagram
   • Overview and diagrams of the electrical system
   • 6-1
2. Map-Controlled CDI Unit
   • Function and troubleshooting
   • 6-2
3. Ignition System
   • Inspection and maintenance
   • 6-3
4. TPS (Throttle Position Sensor) System
   • Function and troubleshooting
   • 6-7

Tuning

1. Engine
   • Performance tuning and adjustments
   • 7-1
2. Chassis
   • Suspension and handling adjustments
   • 7-11