wheel YAMAHA YZ450F 2004 Owner's Manual

3 - 42
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
Bearing free play
Exist play → Replace.
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
Steering shaft
Grasp the bottom of the forks and gen-
tly rock the fork assembly back and
forth.
Free play → Adjust steering head.
3. Check:
Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action → Adjust steering ring
nut.
4. Adjust:
Steering ring nut
Steering ring nut adjustment steps:
Remove the number plate.
Remove the handlebar and handle crown.
Loosen the ring nut 1 using the ring nut
wrench 2.
Ring nut wrench:
YU-33975/90890-01403

4 - 69
ENGKICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
KICK AXLE AND SHIFT SHAFT
Extent of removal:1 Kick axle removal2 Kick axle disassembly
3 Shift shaft removal4 Segment removal
Extent of removal Order Part name Q’ty Remarks
KICK AXLE AND SHIFT SHAFT
REMOVAL
Preparation for removal Oil pump Refer to “OIL PUMP” section.
1 Kick idle gear 1
2 Kick axle assembly 1 Refer to “REMOVAL POINTS”.
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick axle 1
8 Plain washer 1
9 Shift pedal 1
10 Shift shaft 1
11 Collar 1
12 Torsion spring 1
3
2
1
4
1

4 - 71
ENGKICK AXLE AND SHIFT SHAFT
REMOVAL POINTS
EC4B3101
Kick axle assembly
1. Remove:
Kick axle assembly 1
NOTE:
Unhook the torsion spring 2 from the hole a
in the crankcase.
EC4C3101
Shift guide and shift lever assembly
1. Remove:
Bolt (shift guide)
Shift guide 1
Shift lever assembly 2
NOTE:
The shift lever assembly is disassembled at
the same time as the shift guide.
EC4N3100
Segment
1. Remove:
Bolt (segment) 1
Segment 2
NOTE:
Turn the segment counterclockwise until it
stops and loosen the bolt.
INSPECTION
EC4C4200
Kick axle and ratchet wheel
1. Check:
Ratchet wheel 1 smooth movement
Unsmooth movement → Replace.
Kick axle 2
Wear/damage → Replace.
Spring 3
Broken → Replace.
EC4C4300
Kick gear, kick idle gear and ratchet wheel
1. Inspect:
Kick gear 1
Kick idle gear 2
Ratchet wheel 3
Gear teeth a
Ratchet teeth b
Wear/damage → Replace.

4 - 74
ENGKICK AXLE AND SHIFT SHAFT
EC4C5301
Shift shaft
1. Install:
Roller 1
Collar 2
Torsion spring 3
Shift shaft 4
NOTE:
Apply the engine oil on the roller and shift
shaft.
2. Install:
Shift pedal 1
Bolt (shift pedal)
NOTE:
When installing the shift pedal onto the shift shaft,
be sure that the center of the shift pedal is about
1.1 mm (0.04 in) a above the top of the footrest.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
Kick axle assembly
1. Install:
Kick gear 1
Plain washer 2
Circlip 3
Ratchet wheel 4
Spring 5
Plain washer 6
Circlip 7
To kick axle 8.
NOTE:
Apply the molybdenum disulfide oil on the
inner circumferences of the kick gear and
ratchet wheel.
Align the punch mark a on the ratchet wheel
with the punch mark b on the kick axle.
New
New
2. Install:
Torsion spring 1
To kick axle 2.
NOTE:
Make sure the stopper a of the torsion spring
fits into the hole b on the kick axle.

4 - 77
ENGCDI MAGNETO
EC4L3000
REMOVAL POINTS
EC4L3101
Rotor
1. Remove:
Nut (rotor) 1
Plain washer
Use the rotor holding tool 2.
2. Remove:
Rotor 1
Use the flywheel puller 2.
NOTE:
When installing the flywheel puller, turn it
counterclockwise.
Rotor holding tool:
YU-1235/90890-01235
Flywheel puller:
YM-1189/90890-01189
EC4L4000
INSPECTION
EC4L4101
CDI magneto
1. Inspect:
Rotor inner surface a
Stator outer surface b
Damage → Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace CDI magneto and/
or stator.
EC4L4200
Woodruff key
1. Inspect:
Woodruff key 1
Damage → Replace.

4 - 97
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
2. Install:
2nd wheel gear (25T) 1
3rd wheel gear (23T) 2
4th wheel gear (21T) 3
1st wheel gear (27T) 4
O-ring 5
To drive axle 6.
NOTE:
Apply the molybdenum disulfide oil on the
1st, 2nd and 3rd wheel gears inner circum-
ference and on the end surface.
Apply the molybdenum disulfide oil on the
4th wheel gear inner circumference.
Apply the lithium soap base grease on the O-
ring.
3. Install:
Plain washer 1
Circlip 2
NOTE:
Be sure the circlip sharp-edged corner a is
positioned opposite side to the plain washer
and gear b.
Install the circlip with its ends c settled
evenly on the spline crests.
cc
New
4. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
When installing the spacer into the crank-
case, pay careful attention to the crankcase
oil seal lip.

4 - 98
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
5. Install:
Shift fork 1 (L) 1
Shift fork 2 (R) 2
Shift cam 3
To main axle and drive axle.
NOTE:
Apply the molybdenum disulfide oil on the
shift fork grooves.
Mesh the shift fork #1 (L) with the 3rd pinion
gear 4 on the main axle.
Mesh the shift fork #2 (R) with the 4th wheel
gear 5 on the drive axle.
6. Install:
Transmission assembly 1
To crankcase (left) 2.
NOTE:
Apply the engine oil on the bearings and guide
bars.
7. Check:
Shifter operation
Transmission operation
Unsmooth operation → Repair.

5 - 1
CHAS

EC500000
CHASSIS
EC590000
FRONT WHEEL AND REAR WHEEL
EC598000
FRONT WHEEL
FRONT WHEEL AND REAR WHEEL
Extent of removal:
1
Front wheel removal
2
Wheel bearing removal
3
Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
FRONT WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Hose cover 1
2 Bolt (brake hose holder) 2 Only loosening.
3 Bolt (axle holder) 4 Only loosening.
4 Nut (front wheel axle) 1
5 Front wheel axle 1
6 Front wheel 1
7 Collar 2
8 Oil seal 2
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3

5 - 2
CHAS

EC598100
REAR WHEEL
Extent of removal:
1
Rear wheel removal
2
Wheel bearing removal
3
Brake disc removal
Extent of removal Order Part name Q’ty Remarks
Preparation for removal
REAR WHEEL REMOVAL
Hold the machine by placing the
suitable stand under the engine.
WARNING

Support the machine securely so there is no
danger of it falling over.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Chain puller 2
4 Rear wheel 1 Refer to “REMOVAL POINTS”.
5 Collar 2
6 Driven sprocket 1
7 Oil seal 2
8 Circlip 1
9 Bearing 2 Refer to “REMOVAL POINTS”.
10Brake disc
1
2
31
3

FRONT WHEEL AND REAR WHEEL

5 - 3
CHAS

FRONT WHEEL AND REAR WHEEL
EC593000
REMOVAL POINTS
EC523101
Rear wheel
1. Remove:

Wheel
1

NOTE:

Push the wheel forward and remove the drive
chain
2
.
EC513201
Wheel bearing (if necessary)
1. Remove:

Bearing
1

NOTE:

Remove the bearing using a general bearing
puller
2
.
EC594000
INSPECTION
EC514100
Wheel
1. Measure:

Wheel runout
Out of limit
→
Repair/replace.
2. Inspect:

Bearing
Rotate inner race with a finger.
Rough spot/seizure
→
Replace.
NOTE:

Replace the bearings, oil seal and wheel collar
as a set.
Wheel runout limit:
Radial
1
: 2.0 mm (0.08 in)
Lateral
2
: 2.0 mm (0.08 in)