oil filter YAMAHA YZ450F 2003 User Guide

3 - 15
INSP
ADJ
ENGINE OIL REPLACEMENT
5. Start the engine and let it warm up for
several minutes.
CAUTION:
When the oil tank is empty, never start the
engine.
6. Idle the engine more than 10 seconds
while keeping the motorcycle upright.
Then stop the engine and add the oil to
the maximum level.
7. Install:
Oil tank cap
ENGINE OIL REPLACEMENT
1. Start the engine and let it warm up for
several minutes.
2. Stop the engine and place an oil pan
under the drain bolt.
3. Remove:
Oil tank plug 1
Oil filler cap 2
Drain bolt (with gasket) 3
Oil filter drain bolt (O-ring) 4
Drain bolt (with gasket) 5
Drain bolt (with gasket) 6
Drain the crankcase and oil tank
(frame) of its oil.
4. Remove:
Engine skid plate
Engine oil hose clamp 1
Bolt (engine oil hose) 2
Engine oil hose 3
Oil strainer (frame) 4
5. Clean:
Oil strainer (frame)

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INSP
ADJ

ENGINE OIL REPLACEMENT
6. If the oil filter is to be replaced during this
oil change, remove the following parts
and reinstall them.
7. Install:

Plain washer
1


Oil strainer (frame)
2


Engine oil hose
3


Bolt (engine oil hose)
4


Engine oil hose clamp
5


Engine skid plate
8. Install:

Gaskets

Oil filter drain bolt

Drain bolt (crankcase rear)

Drain bolt (crankcase left)

Drain bolt (frame)
9. Fill:

Crankcase
10. Install:

Oil filler plug
11. Inspect:

Engine (for oil leaks)

Oil level
Refer to “ENGINE OIL LEVEL INSPEC-
TION”.
Replacement steps:

Remove the exhaust pipe.

Remove the oil filter cover
1
and oil filter
element
2
.

Check the O-rings
3
, if cracked or dam-
aged, replace them with a new one.

Install the oil filter element and oil filter
cover.
T R..

Oil filter cover:
10 Nm (1.0 m • kg, 7.2 ft • lb)
Oil quantity:
Total amount:
1.2 L (1.06 Imp qt, 1.27 US qt)
Periodic oil change:
1.0 L (0.88 Imp qt, 1.06 US qt)
With oil filter replacement:
1.1 L (0.97 Imp qt, 1.16 US qt)
New
T R..90 Nm (9.0 m · kg, 65 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)

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INSP
ADJ
PILOT SCREW ADJUSTMENT
12. Check:
Oil pressure
Checking steps:
Slightly loosen the oil gallery bolt 1.
Start the engine and keep it idling until oil
starts to seep from the oil gallery bolt. If no
oil comes out after one minute, turn the
engine off so it will not seize.
Check oil passages, oil filter and oil pump
for damage or leakage.
Start the engine after solving the prob-
lem(s) and recheck the oil pressure.
Tighten the oil gallery bolt to specification.
T R..
Oil gallery bolt:
10 Nm (1.0 m • kg, 7.2 ft • lb)
PILOT SCREW ADJUSTMENT
1. Adjust:
Pilot screw 1
Adjusting steps:
NOTE:
To optimize the fuel flow at a smaller throttle
opening, each machine’s pilot screw has
been individually set at the factory. Before
adjusting the pilot screw, turn it in fully and
count the number of turns. Record this num-
ber as the factory-set number of turns out.
Turn in the pilot screw until it is lightly
seated.
Turn out the pilot screw by the factory-set
number of turns.
Pilot screw:
2 turns out (example)

4 - 55
ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)
OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)
Extent of removal:1 Oil filter removal2 Water pump removal
3 Crankcase cover (right) removal
Extent of removal Order Part name Q’ty Remarks
OIL FILTER, WATER PUMP
AND CRANKCASE COVER
(RIGHT) REMOVAL
Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Drain the coolant. Refer to “COOLANT REPLACEMENT”
section in the CHAPTER 3.
Exhaust pipe Refer to “EXHAUST PIPE AND
SILENCER” section.
Brake pedal Refer to “ENGINE REMOVAL” section.
Clutch cover Refer to “CLUTCH” section.
1 Oil filter cover 1
2 Oil filter 1
3 Coolant pipe 2 1
4 Water pump housing 1
5 Pin 2
6 Oil delivery pipe 1
1
2
3

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ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
Extent of removal Order Part name Q’ty Remarks
7 Oil hose 1
8 Kick starter 1
9 Crankcase cover (right) 1
10 Gasket 1
11 Dowel pin/O-ring 4/2
12 Impeller 1
Refer to “REMOVAL POINTS”. 13 Plain washer 1
14 Impeller shaft 1
15 Oil seal 1 1
16 Oil seal 2 1
17 Bearing 1
2
3
2

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ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
REMOVAL POINTS
EC4G3110
Impeller shaft
1. Remove:
Impeller 1
Plain washer 2
Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats a with spanners, etc. and remove the
impeller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discolora-
tion of coolant, or milky transmission oil.
1. Remove:
Bearing 1
Oil seal 2
INSPECTION
EC444200
Impeller shaft
1. Inspect:
Impeller shaft 1
Bend/wear/damage → Replace.
Fur deposits → Clean.

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ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
EC4H4600
Bearing
1. Inspect:
Bearing
Rotate inner race with a finger.
Rough spot/seizure → Replace.
EC444400
Oil seal
1. Inspect:
Oil seal
Wear/damage → Replace.
ASSEMBLY AND INSTALLATION
EC4G5110
Oil seal
1. Install:
Oil seal 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Install the oil seal with its manufacture’s
marks or numbers facing inward.
Bearing
1. Install:
Bearing 1
NOTE:
Install the bearing by pressing its outer race
parallel.
New

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ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
EC4G5220
Impeller shaft
1. Install:
Impeller shaft 1
Plain washer 2
Impeller 3
NOTE:
Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
When installing the impeller shaft, apply the
engine oil on the oil seal lip, bearing and
impeller shaft. And install the shaft while
turning it.
Hold the impeller shaft on its width across
the flats a with spanners, etc. and install the
impeller.
T R..14 Nm (1.4 m · kg, 10 ft · lb)
Crankcase cover (right)
1. Install:
Dowel pin 1
O-ring 2
Collar 3
Gasket 4 New
2. Install:
Crankcase cover (right) 1
Bolt
NOTE:
Apply the engine oil on the impeller shaft
end.
When installing the crankcase cover onto the
crankcase, be sure that the impeller shaft
end 2 aligns with the balancer end slot 3.
Tighten the bolts in stage, using a crisscross
pattern.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
Kick crank
1. Install:
Kick starter 1
Plain washer
Bolt (kick starter)
NOTE:
Install the kick starter so that the kick starter is
as vertical as possible with the distance a
between the kick starter and the frame being
5 mm (0.20 in) or more.
T R..33 Nm (3.3 m · kg, 24 ft · lb)
2. Install:
Oil hose 1
Bolt (oil hose) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
Copper washer 1
Oil delivery pipe 2
Union bolt (M8) 3
Union bolt (M10) 4
New
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..20 Nm (2.0 m · kg, 14 ft · lb)
Water pump housing
1. Install:
Dowel pin 1
O-ring 2 New

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ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
2. Install:
Water pump housing 1
Bolt (water pump housing) 2
Plain washer 3
Coolant drain bolt 4
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
O-ring
Coolant pipe 1
Bolt (coolant pipe) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
Oil filter
1. Install:
Oil filter 1
O-ring 2
Oil filter cover 3
Bolt (oil filter cover)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)