suspension YAMAHA YZ450F 2005 Owners Manual

GEN
INFO
1 - 18
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.
Frame to rear frame
Fuel tank to frame
Silencer to rear frame
Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering shaft to frame
Steering shaft to handle crown
Handle crown to handlebar
Front fork to handle crown
Front fork to under bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of front axle
Tightening of axle holder
Tightening of rear axle
Wheel to sprocket
Caliper to front fork
Brake disc to wheel
Tightening of union bolt
Master cylinder to handlebar
Tightening of air bleeder
Tightening of brake hose holder
Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Master cylinder to frame
Tightening of air bleeder
Tightening of brake hose holder
Fuel tank to fuel cock
Tightening of oil hose clamp Frame construction
Combined seat and tank
Exhaust system
Engine mounting
Steering Steering shaft to
handlebar
Suspension Front Steering shaft to front
fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of
swingarm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel system
Lubrication system

GEN
INFO
POINTS DE VERIFICATION DES COUPLES DE SERRAGE
POINTS DE VERIFICATION DES COUPLES DE SERRAGE
N.B.:
Pour les couples de serrage, se reporter à la section
“CARACTERISTIQUES D’ENTRETIEN” au
CHAPITRE 2.
Cadre au cadre arrière
Réservoir de carburant au cadre
Silencieux au cadre arrière
Cadre au moteur
Support de moteur au moteur
Support de moteur au cadre
Arbre de direction au cadre
Arbre de direction à la couronne de
poignée
Couronne de poignée au guidon
Fourche à la couronne de poignée
Fourche au té inférieur
Ensemble de timonerie
Timonerie au cadre
Timonerie à l’amortisseur
Timonerie au bras oscillant
Amortisseur au cadre
Serrage du boulon-pivot
Serrage de l’axe avant
Serrage du support d’axe
Serrage de l’axe arrière
Roue au pignon
Etrier à la fourche avant
Disque de frein à la roue
Serrage du boulon de raccord
Maître-cylindre au guidon
Serrage du purgeur d’air
Serrage du support de durit de frein
Pédale de frein au cadre
Disque de frein à la roue
Serrage du boulon de raccord
Maître-cylindre au cadre
Serrage du purgeur d’air
Serrage du support de durit de frein
Réservoir de carburant au robinet de
carburant
Serrage du collier de durit d’huile Cadre
Selle et réservoir combinés
Système d’échappement
Bâti moteur
Direction Arbre de direction
vers guidon
Suspension Avant Arbre de direction
vers fourche
Arrière Pour le modèle
à timonerie
Arrière Installation
de l’amortisseur
Arrière Installation
du bras oscillant
Roue Installation de la roue Avant
Arrière
Frein Avant
Arrière
Circuit de carburant
Système de lubrification
1 - 18

SPEC
2 - 3 Transmission:
Primary reduction system Gear
Primary reduction ratio 61/23 (2.652)
Secondary reduction system Chain drive
Secondary reduction ratio 51/14 (3.643)
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 27.1°
Trail 116 mm (4.57 in) (For USA, ZA, AUS, NZ)
117 mm (4.61 in) (For EUROPE except F)
118 mm (4.65 in) (For F, CDN)
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)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
GENERAL SPECIFICATIONS

SPEC
2 - 13
EC212201
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Front fork travel 300 mm (11.8 in)← ----
Fork spring free length 465 mm (18.3 in)← 460 mm (18.1 in)
Spring rate, STD K = 4.5 N/mm
(0.459 kg/mm,
25.7 lb/in)K = 4.4 N/mm
(0.449 kg/mm,
25.1 lb/in)----
Optional spring/spacer Yes← ----
Oil capacity 445 cm
3
(15.7 Imp oz,
15.0 US oz) 455 cm3
(16.0 Imp oz,
15.4 US oz) ----
Oil grade Suspension oil
“S1”← ----
Inner tube outer diameter 48 mm (1.89 in)← ----
Front fork top end Zero mm (Zero in)← ----
Rear suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Shock absorber travel 132 mm
(5.20 in)← ----
Spring free length 260 mm
(10.24 in)← ----
Fitting length 248 mm
(9.76 in)245 mm
(9.65 in)----
240.5 ~ 258.5 mm
(9.47 ~ 10.18 in)← ----
Spring rate, STD K = 52.0 N/mm
(5.30 kg/mm,
296.8 lb/in)K = 50.0 N/mm
(5.10 kg/mm,
285.6 lb/in)----
Optional spring Yes← ----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)← ----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)
MAINTENANCE SPECIFICATIONS

2 - 3
SPECCARACTERISTIQUES GENERALES
Boîte de vitesse:
Système de réduction primaire Pignon
Taux de réduction primaire 61/23 (2,652)
Système de réduction secondaire Transmission par chaîne
Taux de réduction secondaire 51/14 (3,643)
Type de boîte de vitesses Prise constante, 4-rapports
Commande Pied gauche
Rapport de démultiplication: 1ère 27/14 (1,929)
2ème 25/16 (1,563)
3ème 23/18 (1,278)
4ème 21/20 (1,050)
Châssis:
Type de cadre Simple berceau dédoublé
Angle de chasse 27,1°
Chasse 116 mm (4,57 in) (USA, ZA, AUS, NZ)
117 mm (4,61 in) (EUROPE sauf F)
118 mm (4,65 in) (F, CDN)
Pneus:
Type A chambre à air
Taille (avant) 80/100-21 51M (USA, CDN, ZA, AUS, NZ et F)
80/100-21 51R (EUROPE sauf F)
Taille (arrière) 110/90-19 62M (USA, CDN, ZA, AUS, NZ et F)
110/90-19 NHS (EUROPE sauf F)
Pression de gonflage (avant et arrière) 100 kPa (1,0 kgf/cm
2, 15 psi)
Freins:
Type de frein avant Frein monodisque
Commande Main droite
Type de frein arrière Frein monodisque
Commande Pied droit
Suspension:
Suspension avant Fourche télescopique
Suspension arrière Bras oscillant (suspension monocross à bras)
Amortisseur:
Amortisseur avant Ressort hélicoïdal/amortisseur hydraulique
Amortisseur arrière Ressort hélicoïdal/pneumatique, amortisseur
hydraulique
Débattement des roues:
Débattement de roue avant 300 mm (11,8 in)
Débattement de roue arrière 315 mm (12,4 in)
Système électrique:
Système d’allumage Volant magnétique CDI

2 - 13
SPECCARACTERISTIQUES D’ENTRETIEN
CHASSIS
Elément Standard Limite
Système de direction:
Type de roulement de direction Roulement à rouleaux coniques ----
Suspension avant: USA, CDN,
AUS, NZ, ZAEUROPE
Débattement de fourche 300 mm (11,8 in)← ----
Longueur libre de ressort de fourche 465 mm (18,3 in)← 460 mm (18,1 in)
Raideur de ressort, standard K = 4,5 N/mm
(0,459 kg/mm,
25,7 lb/in)K = 4,4 N/mm
(0,449 kg/mm,
25,1 lb/in)----
Ressort/entretoise en option Oui← ----
Capacité d’huile 445 cm
3
(15,7 Imp oz,
15,0 US oz) 455 cm3
(16,0 Imp oz,
15,4 US oz) ----
Type d’huile Huile de fourche
“S1”← ----
Diamètre extérieur du tube plongeur 48 mm (1,89 in)← ----
Extrémité supérieure de la fourche Zéro mm (zéro in)← ----
Suspension arrière: USA, CDN,
AUS, NZ, ZAEUROPE
Débattement d’amortisseur 132 mm
(5,20 in)← ----
Longueur de ressort libre 260 mm
(10,24 in)← ----
Longueur de raccord 248 mm
(9,76 in)245 mm
(9,65 in)----
240,5 à 258,5 mm
(9,47 à 10,18 in)← ----
Raideur de ressort, standard K = 52,0 N/mm
(5,30 kg/mm,
296,8 lb/in)K = 50,0 N/mm
(5,10 kg/mm,
285,6 lb/in)----
Ressort en option Oui← ----
Pression du gaz enfermé1.000 kPa
(10 kg/cm
2,
142 psi)← ----
Bras oscillant:
Limite de jeu du bras oscillant
Extrémité---- 1,0 mm (0,04 in)

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear
ROTOR NUT
Retighten
MUFFLER
Inspect and retighten
Clean
Replace * Whichever comes first
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN
Use chain lube
Chain slack: 48 ~ 58 mm
(1.9 ~ 2.3 in) Lubricate, slack, alignment
Replace
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1. Retighten
AIR FILTER
Use foam air-filter oil or
equivalent oil Clean and lubricate
Replace
OIL FILTER
Replace
OIL STRAINER (frame)
Clean
FRAME
Clean and inspect
FUEL TANK, COCK
Clean and inspect
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid Every one year
FRONT FORKS
Inspect and adjust
Replace oil Suspension oil “S1”
Replace oil sealItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
3

5 - 32
CHASFRONT FORK
EC554600
Outer tube
1. Inspect:
Outer tube 1
Score marks/wear/damage → Replace.
Adjuster
1. Inspect:
Adjuster 1
O-ring 2
Wear/damage → Replace.
EC555000
ASSEMBLY AND INSTALLATION
Front fork assembly
1. Wash the all parts in a clean solvent.
2. Stretch the damper assembly fully.
3. Fill:
Front fork oil 1
To damper assembly.
CAUTION:
Be sure to use recommended fork oil. If
other oils are used, they may have an
excessively adverse effect on the front
fork performance.
Never allow foreign materials to enter the
front fork.
Recommended oil:
Suspension oil “S1”
Oil capacity:
195 cm
3 (6.86 Imp oz, 6.59 US oz)

5 - 39
CHAS
29. Install:
Adjuster 1
To inner tube.
T R..55 Nm (5.5 m · kg, 40 ft · lb)
30. Fill:
Front fork oil 1
From outer tube top.
* For EUROPE
WARNING
Never fail to make the oil amount adjust-
ment between the maximum and minimum
amount and always adjust each front fork
to the same setting. Uneven adjustment
can cause poor handling and loss of stabil-
ity.
CAUTION:
Be sure to use recommended fork oil. If
other oils are used, they may have an
excessively adverse effect on the front
fork performance.
Never allow foreign materials to enter the
front fork.
Recommended oil:
Suspension oil “S1”
Standard oil amount:
260 cm
3 (9.15 Imp oz, 8.79 US oz)
*270 cm3 (9.50 Imp oz, 9.13 US oz)
Extent of adjustment:
200 ~ 300 cm
3
(7.04 ~ 10.6 Imp oz,
6.76 ~ 10.1 US oz)
31. Install:
Damper assembly 1
To outer tube.
NOTE:
Temporarily tighten the damper assembly.
FRONT FORK

7 - 14
TUNSETTING
EC727020
Spring preload adjustment
The spring preload is adjusted by installing the
adjustment washer 1 between the spacer 2
and fork spring 3.
CAUTION:
Do not install three or more adjustment
washers for each front fork.
WARNING
Always adjust each front fork to the same
setting. Uneven adjustment can cause poor
handling and loss of stability.
ÈLoad
ÉFork stroke
1Without adjustment washer (standard)
21 adjustment washer
32 adjustment washers
Standard washer quantity:
Zero adjustment washers
Extent of adjustment:
Zero ~ 2 adjustment washers
EC72A001
Setting of spring after replacement
As the front fork setting can be easily affected
by rear suspension, take care so that the
machine front and rear are balanced (in posi-
tion, etc.) when setting the front fork.
1. Use of soft spring
Generally a soft spring gives a soft riding
feeling. Rebound damping tends to
become stronger and the front fork may
sink deeply over a series of gaps.
To set a soft spring:
Change the rebound damping.
Turn out one or two clicks.
Change the compression damping.
Turn in one or two clicks.