wheel YAMAHA YZ450F 2015 Service Manual

SWINGARM
4-61
EAS1SL5186REMOVING THE SWINGARM
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Measure:
• Swingarm side play
• Swingarm vertical movement
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a. Measure the tightening torque of the pivot
shaft nut.
b. Measure the swingarm side play “a” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
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EAS1SL5187REMOVING THE BEARING
1. Remove:
• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS1SL5188CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage  Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA13770
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check:
• Oil seals
Damage  Replace.
• Bearing
• Spacers
Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set. Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial)
1.0 mm (0.04 in)
T R..

SWINGARM
4-62
EAS1SL5189INSTALLING THE SWINGARM
1. Lubricate:
• Bearing
•Collars
• Spacers
• Oil seal
• Pivot shaft
2. Install:
• Bearing “1”
• Oil seals “2”
(to the swingarm)
TIP
First install the outer and then the inner bear-
ings to a specified depth from inside.
3. Install:
• Swingarm
TIP
Install the pivot shaft from the right.
4. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-7.
5. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-27.Recommended lubricant
Molybdenum disulfide grease
Installed depth “a”
0–0.5 mm (0–0.02 in)
Installed depth “b”
6.5 mm (0.26 in)
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Drive chain slack
50–60 mm (1.97–2.36 in)
New
New
2 22
1 1
aaa
b ba
NewNewNew
T R..

CHAIN DRIVE
4-64
EAS1SL5191REMOVING THE DRIVE CHAIN
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Joint clip
• Drive chain joint “1”
• Drive chain “2”
EAS1SL5192CHECKING THE DRIVE CHAIN
1. Measure:
• 15-link section of the drive chain
Out of specification  Replace the drive
chain.
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a. Measure the length “a” between the inner
sides of the pins and the length “b” between
the outer sides of the pins on a 15-link sec-
tion of the drive chain as shown in the illus-
tration.
b. Calculate the length “c” of the 15-link section
of the drive chain using the following formu-
la.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
TIP
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a differ-
ent location each time.
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2. Check:
•Drive chain
Stiffness  Clean, lubricate, or replace.
3. Clean:
•Drive chain
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a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
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15-link length limit
242.9 mm (9.56 in)

CHAIN DRIVE
4-65
4. Check:
• Drive chain rollers “1”
Damage/wear  Replace the drive chain.
• Drive chain side plates “2”
Damage/wear  Replace the drive chain.
5. Lubricate:
•Drive chain
EAS1SL5193CHECKING THE DRIVE SPROCKET
1. Check:
• Drive sprocket
More than 1/4 tooth wear “a”  Replace the
drive sprocket and the rear wheel sprocket
as a set.
Bent tooth  Replace the drive sprocket
and the rear wheel sprocket as a set.
EAS1SL5194CHECKING THE REAR WHEEL SPROCKET
Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-8.
EAS1SL5195INSTALLING THE DRIVE CHAIN
1. Install:
• Drive chain “1”
• Drive chain joint “2”
• Joint clip “3”
EWA
WARNING
When installing the joint clip, always keep
the direction as shown in the figure.2. Lubricate:
•Drive chain
3. Install:
• Drive sprocket
• Lock washer
• Drive sprocket nut
Refer to “ENGINE REMOVAL” on page 5-1.
ECA1DX1014
NOTICE
Never install a new drive chain onto worn
drive sprockets; this will dramatically short-
en the drive chain’s life.
4. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-27.
ECA13550
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci-
fied limits.
b. Correct
1. Drive chain roller
2. Drive sprocket
New
Drive sprocket nut
75 Nm (7.5 m·kgf, 54 ft·lbf)
Drive chain slack
50–60 mm (1.97–2.36 in)
New
T R..

CLUTCH......................................................................................................... 5-37
REMOVING THE CLUTCH ...................................................................... 5-40
CHECKING THE FRICTION PLATES...................................................... 5-40
CHECKING THE CLUTCH PLATES ........................................................ 5-40
CHECKING THE CLUTCH SPRINGS...................................................... 5-40
CHECKING THE CLUTCH HOUSING ..................................................... 5-41
CHECKING THE CLUTCH BOSS ............................................................ 5-41
CHECKING THE PRESSURE PLATE ..................................................... 5-41
CHECKING THE PUSH LEVER SHAFT .................................................. 5-41
CHECKING THE CLUTCH PUSH RODS ................................................ 5-41
CHECKING THE PRIMARY DRIVE GEAR .............................................. 5-41
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 5-42
INSTALLING THE OIL SEAL................................................................... 5-42
INSTALLING THE RIGHT CRANKCASE COVER ................................... 5-42
INSTALLING THE CLUTCH ..................................................................... 5-42
INSTALLING THE KICKSTARTER LEVER ............................................. 5-45
KICKSTATER................................................................................................. 5-46
REMOVING THE KICK SHAFT ASSEMBLY ........................................... 5-47
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 5-47
CHECKING THE KICK GEAR, KICK IDLE GEAR
AND RATCHET WHEEL ......................................................................... 5-47
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 5-47
INSTALLING THE KICK IDLE GEAR ....................................................... 5-48
SHIFT SHAFT................................................................................................. 5-49
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 5-51
REMOVING THE SEGMENT ................................................................... 5-51
CHECKING THE SHIFT SHAFT .............................................................. 5-51
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 5-51
CHECKING THE STOPPER LEVER ....................................................... 5-51
INSTALLING THE STOPPER LEVER ..................................................... 5-52
INSTALLING THE SEGMENT.................................................................. 5-52
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 5-52
INSTALLING THE SHIFT SHAFT ............................................................ 5-53
INSTALLING THE SHIFT PEDAL ............................................................ 5-53
OIL PUMP AND BALANCER GEAR............................................................. 5-54
REMOVING THE BALANCER ................................................................. 5-56
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT
DRIVE GEAR, AND BALANCER WEIGHT GEAR .................................. 5-56
CHECKING THE BALANCER .................................................................. 5-56
CHECKING THE OIL PUMP .................................................................... 5-56
ASSEMBLING THE OIL PUMP ................................................................ 5-57
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 5-57

ENGINE REMOVAL
5-3
Removing the electronic parts
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case cover
1 Rectifier/regulator 1
2ECU 1
3 Ignition coil 1
4 Condenser 1
5 Neutral switch 1
6 AC magneto coupler 1 Disconnect.
7 Crankshaft position sensor coupler 1 Disconnect.
8 Coolant temperature sensor coupler 1 Disconnect.
For installation, reverse the removal proce-
dure.
T.R.
T.R.
T.R.T.R.
8 3
7
6
154
2
LT

ENGINE REMOVAL
5-4
Removing the engine
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 4-1.
Rear fender Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 5-1.
Air filter case Refer to “THROTTLE BODY” on page 7-5.
Throttle body Refer to “THROTTLE BODY” on page 7-5.
Clutch cable Refer to “CLUTCH” on page 5-37.
Shift pedal Refer to “SHIFT SHAFT” on page 5-49.
1 Engine guard 1
2 Brake pedal 1
3Spring 1
4 Cylinder head breather hose 1
5 Drive sprocket cover 1
6 Drive chain guide 1
New
New
LS
M
8
8
7
6
11
45
New
1 10
3
2

KICKSTATER
5-46
EAS1SL5249
KICKSTATER
Removing the kick shaft
Order Part name Q’ty Remarks
Primary driven gear Refer to “CLUTCH” on page 5-37.
1 Kick idle gear 1
2 Kick shaft assembly 1
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick shaft 1
For installation, reverse the removal proce-
dure.

KICKSTATER
5-47
EAS1SL5250REMOVING THE KICK SHAFT ASSEMBLY
1. Remove:
• Kick shaft assembly “1”
TIP
Unhook the torsion spring “2” from the hole “a”
in the crankcase.
EAS1SL5251CHECKING THE KICK SHAFT AND RATCH-
ET WHEEL
1. Check:
• Ratchet wheel “1” smooth movement
Unsmooth movement  Replace.
• Kick shaft “2”
Wear/damage  Replace the kick shaft as-
sembly.
• Spring “3”
Broken  Replace.
EAS1SL5252CHECKING THE KICK GEAR, KICK IDLE
GEAR AND RATCHET WHEEL
1. Check:
• Kick gear “1”
Wear/damage  Replace the kick shaft as-
sembly.
• Kick idle gear “2”
• Ratchet wheel “3”
• Gear teeth “a”
• Ratchet teeth “b”
Wear/damage  Replace.
EAS1SL5253INSTALLING THE KICK SHAFT ASSEMBLY
1. Install:
• Kick gear “1”
• Washer “2”
• Circlip “3”
• Ratchet wheel “4”
• Spring “5”
• Washer “6”
• Circlip “7”
(to the kick shaft “8”)
TIP
• Apply molybdenum disulfide oil to the inner
circumferences of the kick gear and ratchet
wheel.
• Align the punch mark “a” on the ratchet wheel
with the punch mark “b” on the kick shaft.
2. Install:
• Torsion spring “1”
(to the kick shaft “2”)
TIP
Make sure the stopper “a” of the torsion spring
fits into the hole “b” on the kick shaft.
31
2
a
b
3
12
New
New

KICKSTATER
5-48
3. Install:
• Spring guide “1”
TIP
Slide the spring guide into the kick shaft, make
sure the groove “a” in the spring guide fits on
the stopper of the torsion spring.
4. Install:
• Kick shaft assembly “1”
TIP
• Before installation, apply molybdenum disul-
fide grease to the contacting surfaces of the
kick shaft ratchet wheel guide “2” and the kick
shaft stopper “a”.
• Apply the engine oil on the kick shaft.
• Slide the kick shaft assembly into the crank-
case and make sure the kick shaft stopper “a”
fits into the kick shaft ratchet wheel guide.5. Install:
• Torsion spring “1”
TIP
Turn the torsion spring clockwise and hook into
the proper hole “a” in the crankcase.
EAS1SL5254INSTALLING THE KICK IDLE GEAR
1. Install:
• Kick idle gear “1”
• Washer “2”
• Circlip “3”
TIP
• Apply the engine oil on the kick idle gear inner
circumference.
• Install the kick idle gear with its depressed
side “a” toward you.
1 2a b
New