brake light YAMAHA YZ450F 2005 Owners Manual

GEN
INFO
1 - 1
DESCRIPTION
EC100000
GENERAL INFORMATION
EC110000
DESCRIPTION
1Clutch lever
2Hot starter lever
3Front brake lever
4Throttle grip
5Radiator cap
6Fuel tank cap
7“ENGINE STOP” button
8Kick starter
9Fuel tank
0Radiator
ACoolant drain bolt
BRear brake pedal
CValve joint
DFuel cock
ECold starter knob
FDrive chain
GAir cleaner
HShift pedal
IOil dipstick
JFront forkNOTE:
The machine you have purchased may differ
slightly from those shown in the following.
Designs and specifications are subject to
change without notice.

2 - 25
SPECCABLE ROUTING DIAGRAM
1Master cylinder
2Brake hose holder
3Brake hoseÈInstall the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the caliper.
ÉPass the brake hose into the
brake hose holders.
ÊIf the brake hose contacts the
spring (rear shock absorber),
correct its twist.
ËInstall the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the master cylinder.

3 - 45
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Clutch lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Clutch cable end
0Hot starter cable endÈUse Yamaha cable lube or equivalent on these
areas.
ÉUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÊLubricate the following areas with high quality,
lightweight lithium-soap base grease.
CAUTION:
Wipe off any excess grease, and avoid get-
ting grease on the brake discs.
AAA
AAB
CC

5 - 21
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Brake lever 1
Bolt (brake lever) 2
Nut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the master cylinder piston.
Rear master cylinder
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the master
cylinder.
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
2. Install:
Master cylinder 1
Bolt (master cylinder) 2
3. Install:
Spring 1
Brake pedal 2
O-ring 3
Bolt (brake pedal) 4
Clip 5
NOTE:
Apply the lithium soap base grease on the bolt,
O-ring and brake pedal bracket.
T R..11 Nm (1.1 m · kg, 8.0 ft · lb)
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)

5 - 22
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
Pin 1
Plain washer 2
Cotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
New
Front brake hose
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the caliper.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
2. Install:
Brake hose holder 1
Bolt (brake hose holder) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
Brake hose holder 1
Nut (brake hose holder) 2
NOTE:
Align the top a of the brake hose holder with
the paint b of the brake hose.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)

5 - 23
CHASFRONT BRAKE AND REAR BRAKE
4. Pass the brake hose through the cable
guide 1.
5. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the master
cylinder.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
Rear brake hose
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the caliper.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)