fuel YAMAHA YZ450F 2003 Owner's Guide

4 - 21
ENGCAMSHAFTS
CAMSHAFTS
CYLINDER HEAD COVER
Extent of removal:1 Cylinder head cover removal
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD COVER
REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
1 Spark plug 1
2 Engine upper bracket (right) 1
3 Engine upper bracket (left) 1
4 Cylinder head breather hose 1
5 Oil tank breather hose 1
6 Bolt (cylinder head cover) 2
7 Cylinder head cover 1
8 Gasket 1
9 Timing chain guide (upper) 1
1

4 - 29
ENGCYLINDER HEAD
CYLINDER HEAD
CYLINDER HEAD
Extent of removal:1 Cylinder head removal
NOTE:
Tighten the cylinder head bolts to 30 Nm (3.0 m · kg, 22 ft · lb) in the proper tightening sequence, remove and
retighten the cylinder head bolts to 20 Nm (2.0 m · kg, 14 ft · lb) in the proper tightening sequence, and then
tighten the cylinder head bolts further to reach the specified angle 180˚ in the proper tightening sequence.
Extent of removal Order Part name Q’ty Remarks
CYLINDER HEAD REMOVAL
Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Radiator Refer to “RADIATOR” section.
Carburetor Refer to “CARBURETOR” section.
Camshaft Refer to “CAMSHAFTS” section.
1 Oil delivery pipe 1
2 Nut 2
3* Bolt (L = 150 mm) 2
Refer to NOTE.
4* Bolt (L = 160 mm) 2
5 Cylinder head 1
6 Gasket 1
7 Dowel pin 2
8 Timing chain guide (front) 1
1

4 - 76
ENGCDI MAGNETO
EC4L0000
CDI MAGNETO
Extent of removal:1 CDI magneto removal
Extent of removal Order Part name Q’ty Remarks
CDI MAGNETO REMOVAL
Preparation for removal Seat and fuel tank Refer to “SAET, FUEL TANK AND SIDE
COVERS” section.
Bolt [radiator (left)]
Disconnect the CDI magneto lead.Refer to “RADIATOR” section.
1 Crankcase cover (left) 1
2 Gasket 1
3 Dowel pin 2
4 Nut (rotor) 1 Use special tool.
Refer to “REMOVAL POINTS”.
5 Rotor 1
6 Stator 1
7Woodruff key
1
1

4 - 80
ENGENGINE REMOVAL
EC4M0000
ENGINE REMOVAL
Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for removal Hold the machine by placing the
suitable stand under the frame.
WARNING
Support the machine securely so there is no
danger of it falling over.
Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section.
Carburetor Refer to “CARBURETOR” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
SILENCER” section.
Clutch cable and guide Disconnect at engine side.
Radiator Refer to “RADIATOR” section.
Shift pedal Refer to “CDI MAGNETO” section.
Cylinder head breather hose and
oil tank breather hoseRefer to “CAMSHAFTS” section.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
section in the CHAPTER 3.
Ignition coil
Disconnect the CDI magneto lead.

5 - 44
CHASHANDLEBAR
12. Clamp the clamp portion a of the num-
ber plate to the handlebar.
13. Insert the end of the fuel breather hose 1
into the hole of the number plate.

5 - 58
CHASREAR SHOCK ABSORBER
EC580000
REAR SHOCK ABSORBER
Extent of removal:1 Rear shock absorber removal2 Rear shock absorber disassembly
Extent of removal Order Part name Q’ty Remarks
Preparation for removalREAR SHOCK ABSORBER
REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING
Support the machine securely so there is nodanger of it falling over.
Seat and fitting band Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
Silencer Refer to “EXHAUST PIPE AND
SILENCER” section in the CHAPTER 4.
1 Clamp (air filter joint) 1 Only loosening.
2 Rear frame 1
3 Bolt (rear shock absorber-relay
arm)1 Hold the swingarm.
4 Bolt (rear shock absorber-frame) 1
5 Rear shock absorber 1
6 Locknut 1 Only loosening.
7 Adjuster 1 Only loosening.
8 Spring guide (lower) 1
1
2

–+ELEC

6 - 3
IGNITION SYSTEM
EC620000
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to
ignition system failure and for checking the spark plug which will not spark.
*marked: Only when the ignition checker is used.
NOTE:


Remove the following parts before inspection.
1) Seat
2) Fuel tank

Use the following special tools in this inspection.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112
Spark gap test*Clean or replace
spark plug.
Check entire ignition
system for connection.
(couplers, leads and
ignition coil)Repair or replace.
Check “ENGINE STOP”
button.Replace.
Check ignition coil. Primary coil Replace.
Secondary coil Replace.
Check CDI magneto. Pick-up coil Replace.
Source coil Replace.
Check neutral switch. Repair or replace.
Replace CDI unit.
No spark
OK
OK
OK
OK
OK
Spark
No good
No good
No good
No good
No good
No good
No good

7 - 1
TUN

EC700000
TUNING
EC710000
ENGINE
Carburetor setting

The air/fuel mixture will vary depending on
atmospheric conditions. Therefore, it is nec-
essary to take into consideration the air pres-
sure, ambient temperature, humidity, etc.,
when adjusting the carburetor.

Perform a test run to check for proper engine
performance (e.g., throttle response) and
spark plug(-s) discoloration or fouling. Use
these readings to determine the best possi-
ble carburetor setting.
NOTE:

It is recommended to keep a record of all car-
buretor settings and external conditions (e.g.,
atmospheric conditions, track/surface condi-
tions, lap times) to make future carburetor set-
ting easier.
WARNING


The carburetor is a part of the fuel line.
Therefore, be sure to install it in a well-
ventilated area, away from flammable
objects and any sources of fire.

Never look into the carburetor intake.
Flames may shoot out from the pipe if the
engine backfires while it is being started.
Gasoline may be discharged from the
accelerator pump nozzle when the carbu-
retor has been removed.
SETTING

7 - 2
TUN
CAUTION:


The carburetor is extremely sensitive to
foreign matter (dirt, sand, water, etc.).
During installation, do not allow foreign
matter to get into the carburetor.

Always handle the carburetor and its
components carefully. Even slight
scratches, bends or damage to carbure-
tor parts may prevent the carburetor from
functioning correctly. Carefully perform
all servicing with the appropriate tools
and without applying excessive force.

When the engine is stopped or when
riding at no load, do not open and close
the throttle unnecessarily. Otherwise, too
much fuel may be discharged, starting
may become difficult or the engine may
not run well.

After installing the carburetor, check that
the throttle operates correctly and opens
and closes smoothly.
Atmospheric conditions and carburetor
settings
The air density (i.e., concentration of oxygen
in the air) determines the richness or lean-
ness of the air/fuel mixture. Therefore, refer
to the above table for mixture settings.
That is:

Higher temperature expands the air with its
resultant reduced density.

Higher humidity reduces the amount of oxy-
gen in the air by so much of the water vapor
in the same air.

Lower atmospheric pressure (at a high alti-
tude) reduces the density of the air.
Air temp. HumidityAir
pressure
(altitude)Mixture Setting
High High Low (high) Richer Leaner
Low Low High (low) Leaner Richer
SETTING

7 - 3
TUN

SETTING
Effects of the setting parts on the throttle
valve opening
1
Pilot screw/pilot jet
2
Throttle valve cutaway
3
Jet needle
4
Main jet
ÅClosed
ıFully open
1/2 3/4 1/4 1/8
1
2
3
4
Åı
Main system
The FLATCR carburetor has a primary main
jet. This type of main jet is perfect for racing
motorcycles since it supplies an even flow of
fuel, even at full load. Use the main jet and the
jet needle to set the carburetor.

1
Jet needle
2
Pilot air jet
3
Needle jet
4
Main jet
5
Pilot jet
6
Pilot screw