oil YAMAHA YZ450F 2011 User Guide

2-2
GENERAL SPECIFICATIONS
Fuel:Type Premium unleaded gasoline only
Tank capacity 6.2 L (1.40 Imp gal, 1.64 US gal)
Throttle body: Type 30RA
Manufacturer KEIHIN
Spark plug: Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7–0.8 mm (0.028–0.031 in)
Clutch type: Wet, multiple-disc
Transmission: Primary reduction system Gear
Primary reduction ratio 61/23 (2.652)
Secondary reduction system Chain drive
Secondary reduction ratio 48/13 (3.692) (For USA, CDN)
49/13 (3.769) (For EUROPE, AUS, NZ, ZA)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 27/14 (1.929)
2nd 23/15 (1.533)
3rd 23/18 (1.278)
4th 24/22 (1.091)
5th 20/21 (0.952)
Chassis: USA, CDN EUROPE AUS, NZ, ZA Frame type Semi double cra- dle←←
Caster angle 26.9° 26.8° 26.9°
Trail 118.6 mm (4.67 in)117.5 mm (4.63
in)119.0 mm (4.69
in)
Tire: Type With tube
Size (front) 80/100-21 51M
Size (rear) 120/80-19 63M (F or USA, CDN, AUS, NZ, ZA)
110/90-19 62M (For EUROPE)
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

2-6
MAINTENANCE SPECIFICATIONS
Piston:
Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in) 0.1 mm (0.004
in)
Piston size "D" 96.965–96.980 mm (3.8175–3.8181 in) ----
Measuring point "H" 9.0 mm (0.354 in) ----
Piston off-set Zero mm (Zero in) ----
Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in) 18.045 mm
(0.7104 in)
Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in) 17.971 mm
(0.7075 in)
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B × T) 1.00 × 3.30 mm (0.04 × 0.13 in) ----
End gap (installed) 0.20–0.30 mm (0.008–0.012 in) 0.55 mm (0.022
in)
Side clearance (installed) 0.015–0.065 mm (0.0006–0.0026 in) 0.120 mm
(0.0047 in)
2nd ring:
Type Taper ----
Dimensions (B × T) 1.00 × 3.10 mm (0.04 × 0.12 in) ----
End gap (installed) 0.35–0.50 mm (0.014–0.020 in) 0.85 mm (0.033
in)
Side clearance 0.020–0.060 mm (0.0008–0.0024 in) 0.120 mm
(0.0047 in)
Oil ring:
Dimensions (B × T) 1.5 × 2.55 mm (0.06 × 0.10 in) ----
End gap (installed) 0.20–0.50 mm (0.008–0.020 in) ----Item Standard Limit

2-7
MAINTENANCE SPECIFICATIONS
Crankshaft:
Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ----
Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002
in)
Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02
in)
Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08
in)
Balancer:
Balancer drive method Gear ----
Air filter oil grade: Foam-air-filter oil or equivalent oil ----
Clutch:
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110
in)
Quantity 8 ----
Clutch plate thickness 1.5–1.7 mm (0.059–0.067 in) ----
Quantity 7 ----
Warp limit ---- 0.1 mm (0.004
in)
Clutch spring free length 50.0 mm (1.97 in) 49.0 mm (1.93
in)
Quantity 6 ----
Clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ----
Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm (0.002
in)
Kickstarter:
Type Kick and ratchet type ----
Fuel pump:
Fuel pressure 324 kPa (3.24 kg/cm
2, 46.1 psi) ----
Fuel injector:----
Model/manufacturer 1010/DENSO ----
Throttle body:----
I. D. mark 33D1 00 ----
Manufacturer KEIHIN ----Item Standard Limit

2-8
MAINTENANCE SPECIFICATIONS
Throttle position sensor:----
Throttle position sensor maximum resistance 5 kΩ----
Throttle position sensor variable resistance 0–2 kΩ (full closed) ----
Throttle position sensor input voltage 4–6 V ----
Fuel injection sensor:----
Crankshaft position sensor resistance 248–372 Ω----
Intake air pressure sensor output voltage 3.57–3.71 V at 101.3kPa (1.013 kg/cm
2,
14.41 psi)----
Atmospheric pressure sensor output voltage 3.57–3.71 V at 101.3kPa (1.013 kg/cm
2,
14.41 psi)----
Intake air temperature sensor 5.4–6.6 kΩat 0 °C (32 °F)
290–390 Ωat 80 °C (176 °F)----
Idling condition:----
Engine idle speed 1,900–2,100 r/min ----
Oil temperature 55–65 °C (131–149 °F) ----
Throttle cable free play 3–5 mm (0.12–0.20 in) ----
Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008
in)
Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009
in)
Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm (0.007
in)
Bypass valve setting pressure 40–80 kPa (0.4–0.8 kg/cm
2, 5.69–11.38
psi)----
Cooling:
Radiator core size
Width 121.4 mm (4.78 in) ----
Height 235 mm (9.25 in) ----
Thickness 28 mm (1.10 in) ----
Radiator cap opening pressure 108–137 kPa (1.08–1.37 kg/cm
2,
15.4–19.5 psi)----
Radiator capacity (total) 0.62 L (0.55 Imp qt, 0.66 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit

2-9
MAINTENANCE SPECIFICATIONS
CHASSIS
Item Standard Limit
Steering system:
Steering bearing typeTaper roller bearing ----
Front suspension: USA, CDN EUROPE, AUS, NZ, ZA
Front fork travel 310 mm (12.2 in)←----
Fork spring free length 470 mm (18.5 in)←465 mm (18.3
in)
Spring rate, STD K = 4.6 N/mm (0.469 kg/
mm, 26.3 lb/in)←----
Optional spring Yes←----
Oil capacity 544 cm
3 (19.1 lmp oz,
18.4 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 EUROPE, AUS, NZ, ZA
Shock absorber travel 132.0 mm (5.20 in)←----
Spring free length 260 mm (10.24 in)←254.8 mm
(10.03 in)
Fitting length 252 mm (9.92 in) 253 mm (9.96 in) ----
Preload length
1.5–18 mm (0.06–0.71
in)←
Spring rate, STD K = 56.0 N/mm (5.7 kg/
mm, 319.2 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)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel typeSpoke wheel ----
Front rim size/material 21 × 1.60/Aluminum ----
Rear rim size/material 19 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08
in)
Lateral ---- 2.0 mm (0.08
in)
Drive chain:
Type/manufacturer DID520DMA2 SDH/DAIDO ----
Number of links 113 links + joint ----
Chain slack 50–60 mm (2.0–2.4 in) ----
Chain length (15 links) ---- 242.9 mm
(9.563 in)

2-10
MAINTENANCE SPECIFICATIONS
ELECTRICALFront disc brake:
Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 9.52 mm (0.375 in) ----
Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height (vertical height above footrest
top)Zero mm (Zero in) ----
Clutch lever free play (lever end) 7–12 mm (0.28–0.47 in) ----
Throttle grip free play3–5 mm (0.12–0.20 in) ---- Item Standard Limit
Item Standard Limit
Ignition system:
Advancer type Electrical ----
AC magneto:
Magneto-model (stator)/manufacturer 33D00/YAMAHA ----
Stator coil resistance (color) 0.60–0.90 Ωat 20 °C (68 °F)
(White–White)----
Crankshaft position sensor resistance (color) 248–372 Ωat 20 °C (68 °F) (Gray–Black) ----
ECU-model/manufacturer 33D0 (USA, CDN) ----
33D4 (EUROPE) ----
33D6 (AUS, NZ, ZA) ----
Ignition coil:
Model/manufacturer F6T541/MITSUBISHI ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 3.57–4.83 Ωat 20 °C (68 °F) ----
Secondary coil resistance 10.71–14.49 kΩat 20 °C (68 °F) ----
Coolant temperature sensor:
Coolant temperature sensor resistance 2.51–2.78 kΩat 20 °C (68 °F) ----
210–220 kΩat 100 °C (212 °F) ----

2-11
TIGHTENING TORQUES
TIGHTENING TORQUES
ENGINE
△- marked portion shall be checked for torque tightening after break-in or before each race.
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 8 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 2 28 2.8 20
Oil passage plug M8 × 1.25 1 15 1.5 11
Cylinder head (stud bolt) M6 × 1.0 3 7 0.7 5.1
Cylinder head (bolt) M10 × 1.25 4 Refer to TIP.
*1
Cylinder head (bolt) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 3 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Timing chain guide stopper plate (exhaust side) M6 × 1.0 2 10 1.0 7.2
Exhaust pipe (nut) M6 × 1.0 3 10 1.0 7.2
Exhaust pipe and frame M8 × 1.25 1 20 2.0 14
△Silencer M8 × 1.25 2 30 3.0 22
Silencer clamp (front) M8 × 1.25 1 12 1.2 8.7
Silencer clamp (rear) M8 × 1.25 1 16 1.6 11
Starter knob/Idle screw M12 × 1.0 1 2 0.2 1.4
Throttle body joint M6 × 1.0 2 10 1.0 7.2
Throttle body joint clamp M5 × 0.8 1 3 0.3 2.2
△Air filter case M6 × 1.0 3 7 0.7 5.1
Air filter case cover M5 × 0.8 2 5 0.5 3.6
Air filter joint clamp M4 × 0.7 1 4 0.4 2.2
Throttle cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Throttle cable (pull) M10 × 1.25 1 7 0.7 5.1
Throttle cable (return) M10 × 1.25 1 7 0.7 5.1
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Air duct M6 × 1.0 3 7 0.7 5.1
Radiator M6 × 1.0 4 10 1.0 7.2
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Radiator pipe 1 M6 × 1.0 1 10 1.0 7.2
Radiator pipe 2 M6 × 1.0 1 10 1.0 7.2
Impeller M8 × 1.25 1 14 1.4 10
Water pump housing cover M6 × 1.0 4 10 1.0 7.2
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 2 10 1.0 7.2
Oil pump drive gear shaft M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil pressure check bolt M6 × 1.0 2 10 1.0 7.2

2-12
TIGHTENING TORQUES
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, remove and retighten
the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head
bolts further to reach the specified angle 150° in the proper tightening sequence.
Crankshaft end accessing screw M36 × 1.5 1 10 1.0 7.2
Timing mark accessing screw M14 × 1.5 1 6 0.6 4.3
Clutch cover M6 × 1.0 7 10 1.0 7.2
Right crankcase cover M6 × 1.0 9 10 1.0 7.2
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Crankcase M6 × 1.0 13 12 1.2 8.7
Clutch cable holder M6 × 1.0 2 10 1.0 7.2
Oil drain bolt M8 × 1.25 1 20 2.0 14
Oil drain bolt M8 × 1.25 1 20 2.0 14
Oil check bolt (crankcase) M6 × 1.0 1 10 1.0 7.2
Oil strainer M6 × 1.0 1 10 1.0 7.2
Oil nozzle M5 × 0.8 1 8 0.8 5.8
Crankcase bearing stopper M6 × 1.0 8 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M8 × 1.25 4 22 2.2 16
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Screw (kickstarter crank) M6 × 1.0 1 7 0.7 5.1
Primary drive gear M20 × 1.0 1 100 10.0 72
Clutch boss M20 × 1.0 1 75 7.5 54
Clutch cable locknut M8 × 1.25 1 7 0.7 5.1
Clutch cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Clutch spring M6 × 1.0 6 10 1.0 7.2
Balancer M10 × 1.0 1 45 4.5 32
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Balancer weight M6 × 1.0 3 10 1.0 7.2
Drive sprocket M20 × 1.0 1 75 7.5 54
Drive chain sprocket cover M6 × 1.0 2 7 0.7 5.1
Shift pedal M6 × 1.0 1 12 1.2 8.7
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb

2-15
TIGHTENING TORQUES
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen
the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
ELECTRICAL △Rear fender (front) M6 × 1.0 3 7 0.7 5.1
△Rear fender (rear) M6 × 1.0 2 18 1.8 13
△Mud flap — 2 1 0.1 0.7
△Number plate M6 × 1.0 1 7 0.7 5.1Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Stator M5 × 0.8 3 8 0.8 5.8
Rotor M12 × 1.25 1 65 6.5 47
Crankshaft position sensor M6 × 1.0 2 10 1.0 7.2
Throttle position sensor M5 × 0.8 1 3 0.3 2.2
Injector M5 × 0.8 2 3 0.3 2.2
Ignition coil M5 × 0.8 2 4 0.4 2.9
Coolant temperature sensor M10 × 1.25 1 16 1.6 11
Rectifier/regulator M6 × 1.0 2 7 0.7 5.1
Ignition coil bracket M6 × 1.0 2 10 1.0 7.2
Intake air pressure sensor M5 × 0.8 1 5 0.5 3.6
Atmospheric pressure sensor M5 × 0.8 1 4 0.4 2.9
Atmospheric pressure sensor bracket M6 × 1.0 1 7 0.7 5.1
Condenser bracket M6 × 1.0 2 7 0.7 5.1
Ground lead M5 × 0.8 1 4 0.4 2.9
ECU M5 × 0.8 2 4 0.4 2.9
ECU bracket M6 × 1.0 2 7 0.7 5.1

2-17
LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1. Oil strainer
2. Oil check bolt
3. Scavenging pump
4. Oil feed pump
5. Oil filter element
6. Crankshaft
7. Oil nozzle
8. Exhaust camshaft
9. Intake camshaft10. Main axle
11. Drive axle
12. Oil level check window
13. Oil tank