Chain size YAMAHA YZ450F 2003 Owners Manual

SPEC

2 - 2
GENERAL SPECIFICATIONS
Oil capacity:
Engine oil
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)
Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes): 1.2 L (1.06 Imp qt, 1.27 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a research
octane number of 95 or higher.(Except for ZA)
Premium gasoline (For ZA)
Tank capacity 7.0 L (1.54 Imp gal, 1.85 US gal)
Carburetor:
Type FCR MX39
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission: USA, CDN, ZA,
AUS, NZEUROPE
Primary reduction system Gear
←
Primary reduction ratio 62/22 (2.818)
←
Secondary reduction system Chain drive
←
Secondary reduction ratio 48/14 (3.429) 47/14 (3.357)
Transmission type Constant mesh,
4-speed
←
Operation Left foot operation
←
Gear ratio: 1st 27/14 (1.929)
←
2nd 25/16 (1.563)
←
3rd 23/18 (1.278)
←
4th 21/20 (1.050)
←
Chassis:
Frame type Semi double cradle
Caster angle 27.2˚
Trail 118 mm (4.65 in)
Tire:
Type With tube
Size (front) 80/100-21 51M (For USA, CDN, ZA, AUS, NZ
and F)
80/100-21 51R (For EUROPE except F)
Size (rear) 110/90-19 62M (For USA, CDN, ZA, AUS, NZ
and F)
110/90-19 NHS (For EUROPE except F)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2

, 15 psi)

2

SPEC

2 - 4
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm
(0.002 in)
Cylinder:
Bore size 95.00 ~ 95.01 mm
(3.7402 ~ 3.7406 in)----
Out of round limit ---- 0.05 mm
(0.002 in)
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000 ~ 22.021 mm
(0.8661 ~ 0.8670 in)----
Camshaft journal diameter 21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)----
Shaft-to-cap clearance 0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)0.08 mm
(0.003 in)
Cam dimensions
Intake“A”31.200 ~ 31.300 mm
(1.2283 ~ 1.2323 in)31.100 mm
(1.2244 in)
“B”22.550 ~ 22.650 mm
(0.8878 ~ 0.8917 in)22.450 mm
(0.8839 in)
Exhaust“A”30.950 ~ 31.050 mm
(1.2185 ~ 1.2224 in)30.850 mm
(1.2146 in)
“B”22.494 ~ 22.594 mm
(0.8856 ~ 0.8895 in)22.394 mm
(0.8817 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
A
B

SPEC

2 - 11
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S
×
1.0 1 13 1.3 9.4
Camshaft cap M6
×
1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12
×
1.0 1 37 3.7 27
Cylinder head (stud bolt) M6
×
1.0 2 7 0.7 5.1
M8
×
1.25 1 15 1.5 11
(bolt) M10
×
1.25 4 Refer to NOTE.*
1

(nut) M6
×
1.0 2 10 1.0 7.2
Cylinder head cover M6
×
1.0 2 10 1.0 7.2
Cylinder M6
×
1.0 1 10 1.0 7.2
Timing chain tensioner M6
×
1.0 2 10 1.0 7.2
Tensioner cap bolt M6
×
1.0 1 7 0.7 5.1
Timing chain guide (rear) M6
×
1.0 2 10 1.0 7.2
Exhaust pipe (nut) M8
×
1.25 1 13 1.3 9.4
(bolt) M8
×
1.25 1 24 2.4 17
Silencer M8
×
1.25 2 35 3.5 25
Silencer clamp M8
×
1.25 1 20 2.0 14
Exhaust pipe protector M6
×
1.0 3 10 1.0 7.2
Clamp (cylinder head side) M5
×
0.8 1 3 0.3 2.2
Clamp (carburetor side) M4
×
0.7 1 3 0.3 2.2
Air filter case M6
×
1.0 2 8 0.8 5.8
Air filter joint clamp M6
×
1.0 1 3 0.3 2.2
Air filter joint and air filter case M5
×
0.8 1 4 0.4 2.9
Throttle cable cover M5
×
0.8 2 4 0.4 2.9
Hot starter plunger M12
×
1.0 1 2 0.2 1.4
Air filter element M6
×
1.0 1 2 0.2 1.4
Radiator panel (upper) M6
×
1.0 2 10 1.0 7.2
Radiator M6
×
1.0 6 10 1.0 7.2
Radiator hose clamp M6
×
1.0 8 2 0.2 1.4
Radiator pipe 1, 2 M10
×
1.0 2 10 1.0 7.2
Impeller M8
×
1.25 1 14 1.4 10
Water pump housing cover M6
×
1.0 3 10 1.0 7.2
Coolant drain bolt M6
×
1.0 1 10 1.0 7.2
Oil pump cover M4
×
0.7 1 3 0.3 2.2
Oil pump M6
×
1.0 3 10 1.0 7.2
Engine oil drain bolt (oil filter) M6
×
1.0 1 10 1.0 7.2
Oil filter cover M6
×
1.0 2 10 1.0 7.2
Oil delivery pipe 1 M10
×
1.25 1 20 2.0 14
M8
×
1.25 2 18 1.8 13
Oil delivery pipe 2 M6
×
1.0 1 10 1.0 7.2
Oil hose M6
×
1.0 2 10 1.0 7.2
Oil check bolt M6
×
1.0 1 10 1.0 7.2
Oil hose clamp–2 2 0.2 1.4
Clutch cover M6 × 1.0 7 10 1.0 7.2

SPEC
2 - 14
MAINTENANCE SPECIFICATIONS
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 21 × 1.60/Aluminum ----
Rear rim size/material 19 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)
Drive chain: USA, CDN,
AUS, NZ, ZAEUROPE
Type/manufacturer DID520DMA2
SDH/DAIDO←----
Number of links 113 links + joint 111 links + joint ----
Chain slack 40 ~ 50 mm
(1.6 ~ 2.0 in)←----
Chain length (10 links) ----←152.5 mm (6.00 in)
Front disc brake:
Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ----0.15 mm (0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height
(vertical height above footrest top)5 mm (0.20 in) ----
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ----
Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----Item Standard Limit

SPEC
2 - 16
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Rear wheel axle and nut M20 × 1.5 1 125 12.5 90
Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30
Nipple (spoke)–72 3 0.3 2.2
Disc cover and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11
Engine mounting:
Engine upper bracket and frame M10 × 1.25 2 55 5.5 40
Engine lower bracket and frame M8 × 1.25 4 34 3.4 24
Engine and frame (front) M10 × 1.25 1 65 6.5 47
Engine and frame (upper) M10 × 1.25 1 55 5.5 40
Engine and frame (lower) M10 × 1.25 1 69 6.9 50
Engine guard (lower) M8 × 1.25 1 23 2.3 17
Engine skid plate mounting M6 × 1.0 6 10 1.0 7.2
CDI unit bracket mounting M6 × 1.0 1 10 1.0 7.2
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
Relay arm and swingarm M14 × 1.5 1 80 8.0 58
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame and frame (upper) M8 × 1.25 1 32 3.2 23
Rear frame and frame (lower) M8 × 1.25 2 29 2.9 21
Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Drive chain tensioner mounting (upper) M8 × 1.25 1 19 1.9 13
Drive chain tensioner mounting (lower) M8 × 1.25 1 20 2.0 14
Chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank mounting M6 × 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1
Fuel tank and hooking screw (fitting band) M6 × 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Seat mounting M8 × 1.25 2 23 2.3 17
Side cover mounting M6 × 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 4 0.4 2.9
Air scoop and radiator panel (lower) M6 × 1.0 2 4 0.4 2.9
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting (front) M6 × 1.0 2 7 0.7 5.1
Rear fender mounting (rear) M6 × 1.0 2 10 1.0 7.2
Number plate M6 × 1.0 1 7 0.7 5.1