wheel YAMAHA YZ450F 2015 Workshop Manual

TRANSMISSION
5-73
2. Install:
• Collar “1”
• 2nd wheel gear (23T) “2”
• 4th wheel gear (24T) “3”
• 3rd wheel gear (26T) “4”
• 5th wheel gear (20T) “5”
• Collar “6”
• 1st wheel gear (27T) “7”
• O-rings “8”
(to the drive axle “9”)
TIP
• Before installation, apply molybdenum disul-
fide oil to the inner and end surface of the idler
gear and to the inner surface of the sliding
gear, then install.
• Apply the lithium-soap-based grease on the
O-ring.
3. Install:
• Washer “1”
• Circlip “2”
TIP
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
gear “b”.
• Install the circlip with its ends “c” settled even-
ly on the spline crests.4. Install:
• Collar “1”
TIP
• Apply the lithium soap base grease on the oil
seal lip.
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5. Install:
• Main axle “1”
• Drive axle “2”
TIP
• Install to the left crankcase simultaneously.
• Apply engine oil to the main axle and the drive
axle bearing.
New
298
3
4
5
6
7
New
M
LS
1
New
21
2
ab
cc
1
2
EE

TRANSMISSION
5-74
6. Install:
• Shift fork 1 (L) “1”
• Shift fork 2 (C) “2”
• Shift fork 3 (R) “3”
• Shift cam “4”
(to the main axle and the drive axle)
TIP
• Apply engine oil to the shift fork grooves.
• Apply engine oil to the shift cam groove and
the bearing contact surface.
• Mesh the shift fork 1 (L) with the 4th wheel
gear “5” and 3 (R) with the 5th wheel gear “7”
on the drive axle.
• Mesh the shift fork 2 (C) with the 3rd pinion
gear “6” on the main axle.7. Install:
• Long shift fork guide bar “1”
• Short shift fork guide bar “2”
• Spring “3”
TIP
• Screw the spring into the shift fork guide bar
lightly beforehand.
• Apply the engine oil on the shift fork guide
bars.
8. Check:
• Operation of shift cam and shift fork
• Transmission operation
Unsmooth operation  Repair.
3
12
EE
E
2 13
E

TROUBLESHOOTING
9-3
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
Chassis
1. Brake(s)
• Dragging brake
Electrical system
1. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty ECU
• Faulty coolant temperature sensor
EAS1SL5360OVERCOOLING
Cooling system
• Faulty coolant temperature sensor
EAS1SL5361POOR BRAKING PERFORMANCE
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Defective master cylinder kit
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS1SL5362FAULTY FRONT FORK LEGS
Leaking oil
• Bent, damaged, or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ringMalfunction
• Bent or damaged inner tube
• Bent or damaged outer tube
• Broken fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS1SL5363UNSTABLE HANDLING
1. Handlebar
• Bent or improperly installed handlebar
2. Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg (s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly (-ies)
• Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire (s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
7. Wheel (s)
• Incorrect wheel balance
• Broken or loose spoke
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race

10
TUNING
CHASSIS........................................................................................................ 10-1
SELECTION OF THE SECONDARY REDUCTION
RATIO (SPROCKET) .............................................................................. 10-1
DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ................ 10-1
TIRE PRESSURE..................................................................................... 10-2
FRONT FORK SETTING.......................................................................... 10-2
CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL.......... 10-2
SETTING OF SPRING AFTER REPLACEMENT .................................... 10-3
FRONT FORK SETTING PARTS............................................................. 10-3
REAR SUSPENSION SETTING .............................................................. 10-3
CHOOSING SET LENGTH ...................................................................... 10-3
SETTING OF SPRING AFTER REPLACEMENT .................................... 10-4
REAR SHOCK ABSORBER SETTING PARTS ....................................... 10-5
SUSPENSION SETTING (FRONT FORK)............................................... 10-6
SUSPENSION SETTING (REAR SHOCK ABSORBER) ......................... 10-7

CHASSIS
10-1
EAS1SL5366
CHASSIS
EAS1SL5367SELECTION OF THE SECONDARY REDUC-
TION RATIO (SPROCKET)
*For EUR and JPN
reduction ratio>
• It is generally said that the secondary gear ra-
tio should be reduced for a longer straight por-
tion of a speed course and should be
increased for a course with many corners. Ac-
tually, however, as the speed depends on the
ground condition of the day of the race, be
sure to run through the circuit to set the ma-
chine suitable for the entire course.
• In actuality, it is very difficult to achieve set-
tings suitable for the entire course and some
settings may be sacrificed. Thus, the settings
should be matched to the portion of the
course that has the greatest effect on the race
result. In such a case, run through the entire
course while making notes of lap times to find
the best balance; then, determine the second-
ary reduction ratio.
• If a course has a long straight portion where a
machine can run at maximum speed, the ma-
chine is generally set such that it can develop
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en-
gine over-revving.
TIP
Riding technique varies from rider to rider and
the performance of a machine also vary from
machine to machine. Therefore, do not imitate
other rider’s settings from the beginning but
choose your own setting according to the level
of your riding technique.
EAS1SL5368
DRIVE AND REAR WHEEL SPROCKETS
SETTING PARTS
*For EUR and JPN Secondary reduction ratio = Number of
rear wheel sprocket teeth/Number of
drive sprocket teeth
Secondary reduction ra-
tio3.692 (48/13)
*3.769 (49/13)
Part name Type Part number
Drive sprocket “1”
(STD) 13T 9383E-13233
Rear wheel
sprocket “2” 47T 17D-25447-50
(STD) 48T 17D-25448-50
*(STD) 49T 17D-25449-50
50T 17D-25450-50
51T 17D-25451-50
52T 17D-25452-50

CHASSIS
10-3
EAS1SL5372SETTING OF SPRING AFTER REPLACE-
MENT
As the front fork setting can be easily affected
by the rear suspension, take care so that the
front and the rear are balanced (in position etc.)
when setting the front fork.
1. Use of soft spring
• Change the rebound damping force.
Turn out one or two clicks.
• Change the compression damping force.
Turn in one or two clicks.
TIP
Generally a soft spring gives a soft riding feel-
ing. Rebound damping tends to become stron-
ger and the front fork may sink deeply over a
series of gaps.
2. Use of stiff spring
• Change the rebound damping force.
Turn in one or two clicks.
• Change the compression damping force.
Turn out one or two clicks.
TIP
Generally a stiff spring gives a stiff riding feel-
ing. Rebound damping tends to become weak-
er, resulting in lack of a sense of contact with
the road surface or in a vibrating handlebar.
EAS1SL5373FRONT FORK SETTING PARTS
• Front fork spring “1”
*Except for USA and CAN
TIP
The I.D. mark (slits) “a” is proved on the end of
the spring.
EAS1SL5374REAR SUSPENSION SETTING
The rear shock absorber setting should be
made depending on the rider’s feeling of an ac-
tual run and the circuit conditions.
The rear suspension setting includes the fol-
lowing two factors:
1. Setting of spring preload
• Change the set length of the spring.
• Change the spring.
2. Setting of damping force
• Change the rebound damping force.
• Change the compression damping force.
EAS1SL5375CHOOSING SET LENGTH
1. Place a stand or a block under the engine to
put the rear wheel above the floor, and mea-
sure the length “a” between the rear wheel
axle center and the rear fender holding bolt. TypeSpring
rate N/
mmPart numberI.D.
Mark
(slits)
SOFT4.5 1SL-23141-20 |-||
4.6 1SL-23141-30 |-|||
STD* 4.71SL-23141-10 —
1SL-23141-40 |-||||
4.8 1SL-23141-50 |-|||||
4.91SL-23141-60 ||-||
STD 5.01SL-23141-90 —
1SL-23141-70 ||-|||
STIFF 5.1 1SL-23141-80 ||-||||
a
1

CHASSIS
10-4
2. Remove the stand or block from the engine
and, with a rider astride the seat, measure
the sunken length “b” between the rear
wheel axle center and the rear fender hold-
ing bolt.
3. Loosen the locknut “1” and make adjustment
by turning the adjuster “2” to achieve the
standard figure from the subtraction of the
length “b” from the length “a”.
TIP
• If the machine is new and after it is broken in,
the same set length of the spring may change
because of the initial fatigue, etc. of the
spring. Therefore, be sure to make reevalua-
tion.
• If the standard figure cannot be achieved by
adjusting the adjuster and changing the set
length, replace the spring with an optional one
and make readjustment.
EAS1SL5376SETTING OF SPRING AFTER REPLACE-
MENT
After replacement, be sure to adjust the spring
to the set length [sunken length 90–100 mm
(3.5–3.9 in)] and set it.
1. Use of soft spring
• Adjust to decrease rebound damping force
to compensate for less spring load. Run with
the rebound damping force adjuster one or
two clicks turned out, and readjust it to suit
your preference.
2. Use of stiff spring
• Adjust to increase rebound damping force to
compensate for greater spring load. Run
with the rebound damping force adjuster
one or two clicks turned in, and readjust it to
suit your preference.
TIP
Adjusting the rebound damping force will be fol-
lowed more or less by a change in the com-
pression damping force. For correction, adjust
to decrease compression damping force.
EWA1DX4002
WARNING
When using a rear shock absorber other
than currently installed, use the one whose
overall length “a” does not exceed the stan-
dard as it may result in faulty performance.
Never use one whose overall length is
greater than standard. Standard figure
90–100 mm (3.5–3.9 in)
Length “a” of standard shock
458.5 mm (18.05 in)