clutch YAMAHA YZ450F 2006 User Guide

2 - 21
SPECCABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Radiator hose 1
3Cylinder head breather hose
4Hose holder
5Radiator hose 4
6Clutch cable
7Connector cover
8Fuel hose
9TPS (throttle position sensor)
lead
0Hot starter cable
ACarburetor breather hose
BCarburetor overflow hoseÈInsert the end of the fuel tank
breather hose into the hole in
the steering shaft.
ÉPass the cylinder head breather
hose on the outside of the radia-
tor hose 1 and between the radi-
ator hose 4 and frame.
ÊAlign the paint on the cylinder
head breather hose with the
front edge of the hose holder.
ËPass the clutch cable through
the cable guide.ÌPass the clutch cable in front of
the radiator mounting boss.
ÍInstall the connector cover so
that it does not come in between
the radiator hose 1 and radiator.
ÎPass the fuel hose between the
hot starter cable and TPS lead.
ÏPass the carburetor breather
hoses and overflow hose so that
all there hoses do not contact
the rear shock absorber.
B
AA
B
Ï
B
A
0
9
3
2
ÌÉ
1
È
Í
6
5
4 Ë
A
Ê8
Î
7

2 - 22
SPECCABLE ROUTING DIAGRAM
1Hot starter cable
2Clamp
3TPS (throttle position sensor)
lead
4Hump (frame)
5Neutral switch lead
6Engine bracket
7Engine skid plate stay
8CDI magneto lead
9Clutch cable
0Radiator breather hose
ARadiator hose 2
B“ENGINE STOP” button leadCSub wire harness
DGround lead
ECDI unit bracket
FCDI unit
GCable guide
HIgnition coil lead
IThrottle cable
ÈFasten the hot starter cable and
throttle cables onto the frame.
Locate the clamp ends under
the hot starter cable.ÉFasten the hot starter cable,
throttle cables, TPS lead and
ignition coil lead to the frame.
ÊFasten the TPS lead to the
frame behind its hump.
ËPass the TPS lead over the hot
starter cable.
ÌPass the neutral switch lead on
the inside of the engine bracket.
ÍPass the neutral switch lead
over the engine skid plate stay.
C-C
G-G
E
2
Õ
4 58E
É
D GGA
AB
D
5
ÌÍ Í
Í Î
F
E
D
2
2
2
Ï Ð Ò
Ñ Ó
1
G
2
3
4 2
0
8
5
9
8Ë Ê
0
0 8 5
CC
B
È 2
9
FF
Ô
Ô
B-B
A-A
I
H
3
1
C
B
A
0
0
8
5
D-D
3 F-F
6
7
2 5 0

2 - 23
SPECCABLE ROUTING DIAGRAM
ÎFasten the neutral switch lead
and radiator breather hose to
the frame.
ÏFasten the neutral switch lead,
CDI magneto lead and radiator
breather hose to the frame.
ÐFasten the neutral switch lead,
CDI magneto lead, radiator
breather hose and clutch cable
to the frame over the radiator
mounting boss.ÑPass the radiator breather hose
in front of the radiator hose 2, on
the left of the chassis, and then
between the frame and radiator
hose 4.
ÒFasten the sub wire harness and
“ENGINE STOP” button lead to
the CDI unit bracket with the
clamp ends facing downward
behind the location where the
ground lead branches out from
the sub wire harness.ÓFasten the ground lead and
cable guide together to the CDI
unit bracket.
ÔLocate the clamp ends in the
arrowed range.
ÕFasten the neutral switch lead
and CDI magneto lead to the
frame over its hump.
C-C
G-G
E
2
Õ
4 58E
É
D GGA
AB
D
5
ÌÍ Í
Í Î
F
E
D
2
2
2
Ï Ð Ò
Ñ Ó
1
G
2
3
4 2
0
8
5
9
8Ë Ê
0
0 8 5
CC
B
È 2
9
FF
Ô
Ô
B-B
A-A
I
H
3
1
C
B
A
0
0
8
5
D-D
3 F-F
6
7
2 5 0

2 - 26
SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Clamp
3Hot starter cable
4Clutch cable
5“ENGINE STOP” button lead
6Cable guide
7Brake hose
8Hose guideÈFasten the “ENGINE STOP” button lead to the
handlebar.
ÉPass the clutch cable and hot starter cable
through the cable guide.
ÊPass the brake hose in front of the number plate.
ËPass the throttle cables through the cable guide.
ÌPass the clutch cable and hot starter cable
through the cable guide on the number plate.
A
B
C
A
B
C40˚± 10˚
40˚± 10˚
2
È3
2
5
4
2
3
5
6
Ë1
4
5
7
Ê
6
É
Ì
8

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 - 3
INSP
ADJ
MAINTENANCE INTERVALS
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube Lithium base grease
PROTECTOR GUIDE
Replace
REAR SHOCK ABSORBER
(After
rain ride)
Inspect and adjust
LubeMolybdenum disulfide
grease
Replace spring seat Every one year
Retighten
CHAIN GUARD AND ROLLERS
Inspect
SWINGARM
Molybdenum disulfide
grease
Inspect, lube and retighten
RELAY ARM, CONNECTING ROD
Molybdenum disulfide
grease
Inspect, lube and retighten
STEERING HEAD
Inspect free play and retighten
Clean and lube Lithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate Lithium base grease
THROTTLE, CONTROL CABLE
Yamaha cable lube or
SAE 10W-30 motor oil Check routing and connection
Lubricate
HOT STARTER, CLUTCH LEVER
Inspect free playItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks

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 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 ~ 10
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 ~ 11
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 - 9
INSP
ADJ
CLUTCH ADJUSTMENT
NOTE:
Do not apply pressure more than specified
pressure.
Radiator should be filled fully.
4. Inspect:
Pressure
Impossible to maintain the specified pres-
sure for 10 seconds → Repair.
Radiator
Radiator hose joint
Coolant leakage → Repair or replace.
Radiator hose
Swelling → Replace.
EC359020
CLUTCH ADJUSTMENT
1. Check:
Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play
a:
8 ~ 13 mm (0.31 ~ 0.51 in)
2. Adjust:
Clutch lever free play
NOTE:
Before adjustment, expose the adjuster by
moving the boot 3 and cap 4 away.
Make minute adjustment on the lever side
using the adjuster 5.
After adjustment, check proper operation of
clutch lever. Clutch lever free play adjustment steps:
Loosen the locknut 1.
Turn the adjuster 2 until free play a is
within the specified limits.
Tighten the locknut.
T R..
Locknut:
4 Nm (0.4 m  kg, 2.9 ft  lb)

3 - 14
INSP
ADJ
ENGINE OIL LEVEL INSPECTION
4. Inspect:
Oil level
Remove the oil tank cap and check that
engine oil is above the level mark a.
Below the level mark a → Add oil above
the level mark a.
Above the level mark b → Remove the
check bolt 1 and drain the oil until it
stops coming out.
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)
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)
-20
-4-10
140
3010
5020
6830
8640 50
104
122 ˚CTemp.
˚F
10W-30
10W-40
20W-40
20W-50
15W-40

3 - 15
INSP
ADJ
ENGINE OIL REPLACEMENT
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.
a
b
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 the crankcase and oil tank of its oil.