engine oil YAMAHA YZ450F 2005 User Guide

2 - 21
SPECCABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Oil tank breather hose
3Hot starter cable
4Radiator hose 4
5Clutch cable
6Cylinder head breather hose
7Radiator hose 1
8Hose guide
9Brake hose
0“ENGINE STOP” button lead
AClamp
BSub wire harness
CTPS (throttle position sensor)
lead
DNeutral switch lead
EOil hoseFRadiator breather hose
GCDI magneto lead
HCarburetor breather hose
IOverflow hose
ÈInsert the end of the fuel tank
breather hose into the hole in
the steering shaft cap.
ÉPass the hot starter cable
between the cylinder head
breather hose, oil tank breather
hose and ignition coil, then on
the outside of the left engine
bracket.
ÊPass the clutch cable through
the cable guides.ËPass the cylinder head breather
hose on the outside of the radia-
tor hose 1 and on the inside of
the radiator pipe (radiator hose
4).
ÌPass the clutch cable in front of
the lower radiator mounting boss.
ÍFasten the “ENGINE STOP” but-
ton lead and sub wire harness to
the frame at the protecting tube
of the sub wire harness with a
plastic locking tie and cut off the
tie end.
B
0
C-C
D-D
B
A
AB
DD
CC
F
D G
F
D
A
G
A
A
F
AE
A
DC A A A A B A 0
1
2
3
4 5 6 7 89
Ì
Ë
ÊÉ ÈÙÍ
Î
Ï
Ð
Ð Ñ
A
Ô Õ Ø
Ú HIH
E Û
Ò
Ö ×
Ê Ê Ê
Ó

2 - 22
SPECCABLE ROUTING DIAGRAM
ÎFasten the “ENGINE STOP” but-
ton lead and sub wire harness to
the frame at the protecting tube
for the “ENGINE STOP” button
lead with a plastic locking tie and
cut off the tie end.
ÏFasten the sub wire harness and
hot starter cable to the frame at
the white tape for the sub wire
harness with a plastic locking tie
and cut off the tie end.
ÐFasten the sub wire harness to
the frame with a plastic locking
tie and cut off the tie end.
ÑPass the sub wire harness
between the engine brackets.ÒMake sure that the TPS coupler
does not go outside the chassis.
ÓFasten the TPS lead to the
frame with a plastic band.
ÔFasten the neutral switch lead
and oil hose together with a
plastic locking tie and cut off the
tie end.
ÕFasten the neutral switch lead to
the frame with a plastic band.
ÖFasten the neutral switch lead,
CDI magneto lead and radiator
breather hose to the frame with
a plastic band.×Fasten the neutral switch lead,
CDI magneto lead and radiator
breather hose to the frame with
a plastic locking tie and cut off
the tie end.
ØPass the neutral switch lead,
CDI magneto lead and radiator
breather hose between the radi-
ator and frame.
ÙFasten the neutral switch lead
and CDI magneto lead to the
cable guide at their protecting
tubes with a plastic locking tie
and cut off the tie end.
ÚPass the carburetor breather
hoses and overflow hose so that
all there hoses do not contact
the rear shock absorber.
B
0
C-C
D-D
B
A
AB
DD
CC
F
D G
F
D
A
G
A
A
F
AE
A
DC A A A A B A 0
1
2
3
4 5 6 7 89
Ì
Ë
ÊÉ ÈÙÍ
Î
Ï
Ð
Ð Ñ
A
Ô Õ Ø
Ú HIH
E Û
Ò
Ö ×
Ê Ê Ê
Ó

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
ENGINE OIL
Replace
VALVES
The engine must be cold.
Check the valve seats
and valve stems for wear. Check the valve clearances
Inspect
Replace
VALVE SPRINGS
Check the free length and
the tilt. Inspect
Replace
VALVE LIFTERS
Check for scratches and
wear. Inspect
Replace
CAMSHAFTS Inspect the camshaft sur-
face.
Inspect the decompres-
sion system Inspect
Replace
CAMSHAFT SPROCKETS
Check for wear on the
teeth and for damage. Inspect
Replace
PISTON
Inspect crack
Inspect carbon deposits
and eliminate them. Inspect
Clean
Replace
PISTON RING
Check ring end gap Inspect
Replace
PISTON PIN
Inspect
Replace
CYLINDER HEAD Inspect carbon deposits
and eliminate them.
Change gasket Inspect and clean
CYLINDER
Inspect and clean
Inspect score marks
Inspect wear
Replace
CLUTCH
Inspect housing, friction
plate, clutch plate and
spring Inspect and adjust
Replace
TRANSMISSION
Inspect
Replace bearing

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-13
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-13 ~ 17
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10
Brakes Check the play of front brake and effect of front and rear brake. P.3-24 ~ 30
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-31 ~ 33
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-41 ~ 42
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-42 ~ 44
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-33 ~ 40
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks.—
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-31
Lubrication Check for smooth operation. Lubricate if necessary. P.3-45
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 21

3 - 7
INSP
ADJ
RADIATOR CAP INSPECTION
CAUTION:
Do not mix more than one type of ethyl-
ene glycol antifreeze containing corro-
sion inhibitors for aluminum engine.
Do not use water containing impurities or
oil.
7. Install:
Radiator cap
Start the engine and warm it up for a sev-
eral minutes.
8. Check:
Coolant level
Coolant level low → Add coolant. Handling notes of coolant:
The coolant is harmful so it should be han-
dled with special care.
WARNING
When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.
When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.
When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.
EC355000
RADIATOR CAP INSPECTION
1. Inspect:
Seal (radiator cap) 1
Valve and valve seat 2
Crack/damage → Replace.
Exist fur deposits 3 → Clean or replace.

3 - 13
INSP
ADJ
7. Install:
Air filter element 1
Washer
Fitting bolt
NOTE:
Align the projection a on filter guide with the
hole b in air filter case.
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
ENGINE OIL LEVEL INSPECTION
1. Stand the machine on a level surface.
NOTE:
When checking the oil level make sure that
the machine is upright.
Place the machine on a suitable stand.
WARNING
Never remove the oil tank cap just after
high speed operation. The heated oil could
spurt out. causing danger. Wait until the oil
cools down to approximately 70 °C (158 °F).
2. Idle the engine more than 3 minutes while
keeping the machine upright. Then stop the
engine and inspect the oil level.
3. Remove:
Oil tank cap 1
1
ENGINE OIL LEVEL INSPECTION

3 - 14
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
4. Inspect:
Oil level
Oil level should be between maximum a
and minimum b marks.
Oil level low → Add oil to proper level.
NOTE:
When inspecting the oil level, do not screw the
oil level gauge into the oil tank.
Insert the gauge lightly.
(For USA and CDN)
CAUTION:
Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
Do not allow foreign material to enter the
crankcase.
(Except for USA and CDN)
CAUTION:
Do not add any chemical additives or use
oils with a grade of CD
a or higher.
Do not use oils labeled “ENERGY CON-
SERVING II”
b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.
Do not allow foreign materials to enter the
crankcase.
Recommended oil:
At 5 °C (40 °F) or higher
È
Yamalube 4 (20W-40) or SAE
20W-40 type SG motor oil
(Non-Friction modified)
At 15 °C (60 °F) or lower
É
Yamalube 4 (10W-30) or SAE
10W-30 type SG motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)
Recommended oil:
Refer to the following chart for
selection of oils which are
suited to the atmospheric
temperatures.
Recommended engine oil classi-
fication:
API STANDARD:
API “SG” or higher grade
(Designed primarily for
motorcycles)
a
b
-20
-4-10
140
3010
5020
6830
8640 50
104
122 ˚CTemp.
˚F
10W-30
10W-40
20W-40
20W-50
15W-40
a
b

3 - 15
INSP
ADJ
ENGINE OIL REPLACEMENT
5. Start the engine and let it warm up for sev-
eral minutes.
CAUTION:
When the oil tank is empty, never start the
engine.
6. Idle the engine more than 10 seconds
while keeping the machine upright. Then
stop the engine and add the oil to the maxi-
mum level.
7. Install:
Oil tank cap
ENGINE OIL REPLACEMENT
1. Start the engine and let it warm up for sev-
eral 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)

3 - 16
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 Replacement steps:
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:
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)
New
T R..70 Nm (7.0 m · kg, 50 ft · lb)
T R..8 Nm (0.8 m · kg, 5.8 ft · lb)
T R..2 Nm (0.2 m · kg, 1.4 ft · lb)
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)
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)

3 - 17
INSP
ADJ
PILOT SCREW ADJUSTMENT
10. Install:
Oil filler plug
11. Inspect:
Engine (for oil leaks)
Oil level
Refer to “ENGINE OIL LEVEL INSPEC-
TION”.
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:
1-3/4 turns out (example)