YAMAHA YZ450F 2015 Workshop Manual

CHASSIS SPECIFICATIONS
2-8
EAS1SL5055
CHASSIS SPECIFICATIONS
Chassis
Frame type Semi double cradle
Caster angle 27.08 ° (USA) (CAN)
27.50 ° (EUR)
27.67 ° (JPN)
27.58 ° (AUS) (NZL) (ZAF)
Trail 120 mm (4.7 in) (USA) (CAN)
122 mm (4.8 in) (EUR)
124 mm (4.9 in) (JPN) (AUS) (NZL) (ZAF)
Front wheel
Wheel type Spoke wheel
Rim size 21  1.60
Rim material Aluminum
Wheel travel 310 mm (12.2 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Rear wheel
Wheel type Spoke wheel
Rim size 19  2.15
Rim material Aluminum
Wheel travel 315 mm (12.4 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Front tire
Type With tube
Size 80/100-21 51M
Manufacturer/model DUNLOP/MX52F (USA) (CAN)
PIRELLI/MID SOFT 32 (EUR)
BRIDGESTONE/M601 (JPN)
DUNLOP/MX52F (AUS) (NZL) (ZAF)
Rear tire
Type With tube
Size 120/80-19 63M (USA) (CAN)
110/90-19 62M (EUR) (JPN)
120/80-19 63M (AUS) (NZL) (ZAF)
Manufacturer/model DUNLOP/MX52 (USA) (CAN)
PIRELLI/MID SOFT 32 (EUR)
BRIDGESTONE/M602 (JPN)
DUNLOP/MX52 (AUS) (NZL) (ZAF)
Tire air pressure (measured on cold tires)
Front 100 kPa (1.00 kgf/cm2, 15 psi)
Rear 100 kPa (1.00 kgf/cm2, 15 psi)
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter  thickness 250  3.0 mm (9.8  0.12 in)

CHASSIS SPECIFICATIONS
2-9
Brake disk thickness limit 2.5 mm (0.10 in)
Brake pad lining thickness (inner) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 9.52 mm (0.37 in)
Caliper cylinder inside diameter 22.65 mm  2 (0.89 in  2)
Recommended brake fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Rear disc brake
Disc outside diameter  thickness 245  4.0 mm (9.6  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm  1 (1.00 in  1)
Recommended fluid DOT 4
Steering
Steering bearing type Taper roller bearing
Center to lock angle (left) 43.0 °
Center to lock angle (right) 43.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 310.0 mm (12.20 in)
Fork spring free length 497.0 mm (19.57 in)
Limit 492.0 mm (19.37 in)
Installed length 497.0 mm (19.57 in)
Spring rate K1 5.00 N/mm (0.51 kgf/mm, 28.55 lbf/in) (USA)
(CAN)
4.70 N/mm (0.48 kgf/mm, 26.84 lbf/in) (EUR)
(JPN) (AUS) (NZL) (ZAF)
Spring stroke K1 0.0–310.0 mm (0.00–12.20 in)
Inner tube outer diameter 48 mm (1.9 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available Yes
Recommended oil Suspension oil S1
Standard oil amount 511.0 cm
3 (17.28 US.oz, 18.02 Imp.oz) (USA)
(CAN)
551.0 cm
3 (18.63 US.oz, 19.43 Imp.oz) (EUR)
(JPN) (AUS) (NZL) (ZAF)
Rebound damping adjusting positions
* Position in which the adjuster is turned in finger tight
Minimum 20 click (s) out*
Standard 10 click (s) out* (USA) (CAN)
8 click (s) out* (EUR) (JPN) (AUS) (NZL) (ZAF)
Maximum (hard) Fully turned in

CHASSIS SPECIFICATIONS
2-10
Compression damping adjusting positions
* Position in which the adjuster is turned in finger tight
Minimum 20 click (s) out*
Standard 8 click (s) out*
Maximum (hard) Fully turned in
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 132.0 mm (5.20 in)
Spring free length 275.0 mm (10.83 in)
Spring rate K1 58.00 N/mm (5.91 kgf/mm, 331.18 lbf/in) (USA)
(CAN)
56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in) (EUR)
(JPN) (AUS) (NZL) (ZAF)
Spring stroke K1 0.0–150.0 mm (0.00–5.91 in)
Optional spring available Yes
Enclosed gas/air pressure (STD) 980 kPa (9.8 kgf/cm
2, 139.4 psi)
Spring installed length
Minimum Position in which the spring is turned in 1.5 mm
(0.06 in) from its free length.
Standard Position in which the spring is turned in 10 mm
(0.39 in) from its free length.
Maximum Position in which the spring is turned in 18 mm
(0.71 in) from its free length.
Rebound damping adjusting positions
* Position in which the adjuster is turned in finger tight
Minimum 30 click (s) out*
Standard 14 click (s) out* (USA) (CAN)
12 click (s) out* (EUR) (JPN) (AUS) (NZL)
(ZAF)
Maximum Fully turned in
Compression damping adjusting positions
(for fast compression damping)
* Position in which the adjuster is turned in finger tight
Minimum 2 turn (s) out*
Standard 1-1/2 turn (s) out* (USA) (CAN)
1-1/8 turn (s) out* (EUR) (JPN) (AUS) (NZL)
(ZAF)
Maximum Fully turned in
Compression damping adjusting positions
(for slow compression damping)
* Position in which the adjuster is turned in finger tight
Minimum 20 click (s) out*
Standard 12 click (s) out* (USA) (CAN)
10 click (s) out* (EUR) (JPN) (AUS) (NZL)
(ZAF)
Maximum Fully turned in
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 0.2–0.9 mm (0.01–0.04 in)

CHASSIS SPECIFICATIONS
2-11
Drive chain
Type/manufacturer 520DMA2-SDH/DAIDO
Number of links 114
Drive chain slack 50–60 mm (1.97–2.36 in)
15-link length limit 242.9 mm (9.56 in)

ELECTRICAL SPECIFICATIONS
2-12
EAS1SL5056
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 ° at 2000 r/min
Engine control unit
Model/manufacturer 1SL4/YAMAHA (USA) (CAN)
1SL5/YAMAHA (EUR) (JPN) (AUS) (NZL)
(ZAF)
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 
Secondary coil resistance 8.64–12.96 k
AC magneto
Standard output 14.0 V, 95 W at 5000 r/min
Stator coil resistance 0.624–0.936 
Rectifier/regulator
Regulator type Semi conductor-short circuit
No load regulated voltage 14.1–14.9 V
Rectifier capacity (DC) 23.0 A

TIGHTENING TORQUES
2-13
EAS20320
TIGHTENING TORQUES
EAS1SL5057GENERAL TIGHTENING TORQUE SPECIFI-
CATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided for
each chapter of this manual. To avoid warpage,
tighten multi-fastener assemblies in a criss-
cross pattern and progressive stages until the
specified tightening torque is reached. Unless
otherwise specified, tightening torque specifi-
cations require clean, dry threads. Compo-
nents should be at room temperature.
A. Distance between flats
B. Outside thread diameter
A (nut)B
(bolt)General tightening
torques
Nm m·kgf ft·lbf
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94

TIGHTENING TORQUES
2-14
EAS1SL5058ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
Camshaft cap bolt
M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug
M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plug
M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt (exhaust
pipe)M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head bolts
M9 4 See TIP.
*1
Cylinder head bolts
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover bolt
M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage plug (cylinder head)
M8 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw
M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf)Use a
lock
washer.
Balancer nut M10 1 45 Nm (4.5 m·kgf, 33 ft·lbf)Use a
lock
washer.
Timing chain guide stopper plate
(exhaust side)M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt
M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw
M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump housing cover bolt
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt
M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screw
M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage cover bolt (left crank-
case)M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt
M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint clamp bolt
M5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
LT
M
LT
LT
LT

TIGHTENING TORQUES
2-15
Air filter joint clamp bolt
M4 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air filter case bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter bolt M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air filter guide holder screw
M5 8 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Air filter case cap screw
M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Starter knob/Idle screw
M12 1 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf)
Throttle cable nut (pull)
M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle cable nut (return)
M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Clutch cable adjuster and locknut
M6 1 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf)
Clutch cable locknut (engine side)
M8 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Exhaust pipe nut
M6 3 See TIP.
*2
Exhaust pipe protector screw
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe bracket bolt
M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Frame and silencer bolt (front) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Frame and silencer bolt (rear) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe clamp bolt
M8 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer body bolt
M5 6 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Oil nozzle bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt
M10 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Crankcase bolt
M6 12 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Clutch cable holder bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft end accessing screw
M36 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing mark accessing screw
M14 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Drive chain sprocket cover bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankcase bearing cover plate
screwM6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase bearing cover plate
screw (crankshaft)M8 4 18 Nm (1.8 m·kgf, 13 ft·lbf) Crimp.
Clutch cover bolt
M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil level check window bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Left crankcase cover bolt
M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Right crankcase cover bolt
M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element cover bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil level check window bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Kick shaft ratchet wheel guide bolt
M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Kick starter lever bolt
M8 1 33 Nm (3.3 m·kgf, 24 ft·lbf)
Kick starter lever boss screw
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES RemarksLT
LT
LT
LT
LT
LT
LT

TIGHTENING TORQUES
2-16
Primary drive gear nut
M20 1 100 Nm (10 m·kgf, 72 ft·lbf)
Clutch spring bolt
M6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch boss nut
M20 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
Drive sprocket nut M20 1 75 Nm (7.5 m·kgf, 54 ft·lbf)Use a
lock
washer.
Drive axle oil seal stopper bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Segment
M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Shift guide bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stopper lever bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift pedal bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rotor nut
M12 1 65 Nm (6.5 m·kgf, 47 ft·lbf)
Stator screw
M5 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Crankshaft position sensor bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
AC magneto lead holder bolt
M5 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Coolant temperature sensor
M10 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Neutral switch bolt
M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Intake air temperature sensor screw
M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rectifier/regulator bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ECU bolt
M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Ignition coil bolt
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle position sensor screw
M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Intake air pressure sensor screw
M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf) ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
LT
LT
LT
LT
LT
LT
LT

TIGHTENING TORQUES
2-17
TIP
*1: First, tighten the cylinder head bolts to 30 Nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening se-
quence and remove them. Retighten the cylinder head bolts to 20 Nm (2.0 m·kgf, 14 ft·lbf) in the prop-
er tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle
150° in the proper tightening sequence.
TIP
*2: First temporarily tighten nuts to 7 Nm (0.7 m·kgf, 5.1 ft·lbf). Then retighten them to 10 Nm (1.0
m·kgf, 7.2 ft·lbf).
1
42
3 x4FWD