clutch YAMAHA YZ450F 2014 Owner's Guide

CLUTCH
5-42
CHECKING THE PRIMARY DRIVEN GEAR
1. Check:
• Primary driven gear
Damage/wear  Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation  Re-
place the primary drive and primary driven
gears as a set.
EAS1SL1244INSTALLING THE OIL SEAL
1. Install:
• Oil seal “1”
• Washer “2”
• Circlip “3”
TIP
• Apply is lithium-soap-based grease on the oil
seal lip.
• Install the oil seal in parallel with its manufac-
ture's marks or numbers facing inward.
EAS1SL1245INSTALLING THE RIGHT CRANKCASE
COVER
1. Install:
• Dowel pin “1”
• O-rings “2”
• Collar “3”
• Gasket “4”
TIP
Apply the lithium-soap-based grease on the O-
ring.
2. Install:
• Right crankcase cover “1”
• Right crankcase cover bolt “2”
TIP
• Apply the engine oil on the impeller shaft end.
• When installing the crankcase cover onto the
crankcase, make sure that the impeller shaft
end “3” aligns with the balancer end slot “4.”
• Tighten the right crankcase cover bolts in
stages and in a crisscross pattern.
EAS1SL1246INSTALLING THE CLUTCH
1. Install:
• Push lever shaft “1”
TIP
• Apply the lithium soap base grease on the oil
seal lip.
• Before installation, apply the engine oil to the
push lever shaft sliding surface.
New
New
3
2
1
LS
New
New
1
1 4
2
New
New
3
LS
Right crankcase cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)T R..
12
1

CLUTCH
5-43
2. Install:
• Primary driven gear “1”
• Thrust washer “2”
• Clutch boss “3”
TIP
Apply the engine oil on the primary driven gear
inner circumference.
3. Install:
• Conical washer “1”
• Clutch boss nut “2”
ECA1DX1020
NOTICE
Make sure to tighten to specification; other-
wise, it may damage the other part that is
fastened together.
TIP
• Install the conical washer with its convex sur-
face “a” outward.
• Apply engine oil to the threads and contact
surface of the clutch boss nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Use the clutch holding tool “3” to hold the
clutch boss.
4. Install:
• Friction plate 1 “1”
• Clutch plate “2”
• Friction plate 2 “3”
TIP
• Install the clutch plates and friction plates al-
ternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• From the clutch boss side, install the friction
plates in order: friction plate 1  3, friction
plate 2 (identification color: purple)  3, and
friction plate 1  2.
• Apply the engine oil on the friction plates and
clutch plates.
5. Install:
• Bearing “1”
• Washer “2”
• Circlip “3”
To push rod 1 “4.”
TIP
Apply the engine oil on the bearing and washer.
Clutch boss nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
Clutch holder
90890-04086
YM-91042
New
T R..
a2
3
21
a. Identification color
1
2a
3
2
2
1
New

CLUTCH
5-44
6. Install:
• Push rod 2 “1”
•Ball “2”
• Push rod 1 “3”
TIP
Apply the engine oil on the push rod 1, 2 and
ball.
7. Install:
• Pressure plate “1”
8. Install:
• Clutch spring
• Clutch spring bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
9. Install:
• O-ring “1”
TIP
Apply the lithium-soap-based grease to the O-
ring.
10.Install:
• Clutch cover “1”
• Clutch cover bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
EAS1SL1247
Clutch spring bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)T R..
Clutch cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
New
T R..
1

CLUTCH
5-45
INSTALLING THE KICKSTARTER LEVER
1. Install:
• Kickstarter lever “1”
• Washers
• Bolt (kickstarter lever)
TIP
Install so that there is a clearance “a” of 5 mm
(0.2 in) or more between the kickstarter lever
and the frame and that the kickstarter lever
does not contact the right crankcase cover
when it is pulled.
Bolt (kickstarter lever)
33 Nm (3.3 m·kgf, 24 ft·lbf)T R..
1
a

KICKSTATER
5-46
EAS1SL1248
KICKSTATER
Removing the kick shaft
OrderPart nameQ’tyRemarks
Primary driven gearRefer to “CLUTCH” on page 5-37.
1Kick idle gear1
2Kick shaft assembly1
3Spring guide1
4Torsion spring1
5Ratchet wheel1
6Kick gear1
7Kick shaft1
For installation, reverse the removal proce-dure.
M

SHIFT SHAFT
5-49
EAS1SL1254
SHIFT SHAFT
Removing the shift shaft and stopper lever
OrderPart nameQ’tyRemarks
Primary driven gearRefer to “CLUTCH” on page 5-37.
1Shift pedal1
2Shift shaft1
3Oil seals1
4Collars1
5Shift shaft spring1
6Roller1
7Shift guide1
8Shift lever assembly1
9Shift lever1
10Pawl2
11Pawl pin2
12Spring2
13Stopper lever1
LS
1 3
10 Nm (1.0 m kgf, 7.2 ft lbf)
13
15 14
10 Nm (1.0 m kgf, 7.2 ft lbf)
30 Nm (3.0 m kgf, 22 ft lbf)
LT
610 11 12
118
1210
4
25
LT
7
LT
E
10 Nm (1.0 mkgf, 7.2 ftIbf)T.R.

OIL PUMP AND BALANCER GEAR
5-54
EAS1SL1265
OIL PUMP AND BALANCER GEAR
Removing the oil pump
OrderPart nameQ’tyRemarks
Primary driven gearRefer to “CLUTCH” on page 5-37.
Right crankcase coverRefer to “CLUTCH” on page 5-37.
1Oil pump assembly1
2Oil pump cover1
3Outer rotor1
4Dowel pin1
5Inner rotor1
6Oil pump drive shaft1
7Rotor housing1
For installation, reverse the removal proce-dure.
2.0 Nm (0.20 mkgf, 1.4 ftIbf)T.R.
5 Nm (0.5 mkgf, 3.6 ftIbf)T.
R
.
LT
E
3
2
1
4
5
7
6

OIL PUMP AND BALANCER GEAR
5-55
Removing the balancer
OrderPart nameQ’tyRemarks
Primary driven gearRefer to “CLUTCH” on page 5-37.
Right crankcase coverRefer to “CLUTCH” on page 5-37.
StatorRefer to “AC MAGNETO” on page 5-59.
1Nut (balancer)1
2Nut (primary drive gear)1
3Nut (balancer shaft driven gear)1
4Lock washer1
5Balancer1
6Straight key1
7Conical washer1
8Primary drive gear1
9Balancer shaft drive gear1
10Lock washer1
11Balancer weight gear1
For installation, reverse the removal proce-dure.
45 Nm (4.5 mkgf, 33 ftIbf)T.R.
100 Nm (10 mkgf, 72 ftlbf)T.R.
50 Nm (5.0 mkgf, 36 ftIbf)T.R.
New

WATER PUMP
6-4
EAS1SL1298
WATER PUMP
Removing the water pump
OrderPart nameQ’tyRemarks
CoolantDrain.Refer to “CHANGING THE COOLANT” on page 3-8.
Engine oilDrain.Refer to “CHANGING THE ENGINE OIL” on page 3-15.
Right crankcase coverRefer to “CLUTCH” on page 5-37.
1Water pump housing1
2Dowel pin2
3Gasket1
4Collar1
5Pin1
6Impeller shaft assembly1
7Oil seal1
8Bearing1
9Oil seal1
For installation, reverse the removal proce-dure.
7
6
2
2
3
1
854
10 Nm (1.0 mkgf, 7.2 ftIbf)T.R.
10 Nm (1.0 mkgf, 7.2 ftIbf)T.R.
New
New
New
E
9
New
E

9
TROUBLE SHOOTING
TROUBLE SHOOTING..................................................................................... 9-1
GENERAL INFORMATION ........................................................................ 9-1
STARTING FAILURES ............................................................................... 9-1
INCORRECT ENGINE IDLING SPEED ..................................................... 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ............................ 9-2
FAULTY GEAR SHIFTING ......................................................................... 9-2
SHIFT PEDAL DOES NOT MOVE ............................................................. 9-2
JUMPS OUT OF GEAR.............................................................................. 9-2
FAULTY CLUTCH ...................................................................................... 9-2
OVERHEATING ......................................................................................... 9-2
OVERCOOLING ......................................................................................... 9-3
POOR BRAKING PERFORMANCE ........................................................... 9-3
FAULTY FRONT FORK LEGS ................................................................... 9-3
UNSTABLE HANDLING ............................................................................. 9-3
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS............................. 9-4