engine oil YAMAHA YZ450F 2016 User Guide

ENGINE SPECIFICATIONS
2-4
Valve spring
Free length (intake) 40.76 mm (1.60 in)
Limit 38.72 mm (1.52 in)
Free length (exhaust) 36.94 mm (1.45 in)
Limit 35.09 mm (1.38 in)
Installed length (intake) 34.78 mm (1.37 in)
Installed length (exhaust) 30.83 mm (1.21 in)
Spring rate K1 (intake) 31.90 N/mm (3.25 kgf/mm, 182.15 lbf/in)
Spring rate K2 (intake) 41.37 N/mm (4.22 kgf/mm, 236.22 lbf/in)
Spring rate K1 (exhaust) 21.76 N/mm (2.22 kgf/mm, 124.25 lbf/in)
Spring rate K2 (exhaust) 28.12 N/mm (2.87 kgf/mm, 160.57 lbf/in)
Installed compression spring force (intake) 178.00–204.00 N (18.15–20.80 kgf,
40.01–45.86 lbf)
Installed compression spring force (exhaust) 124.00–142.00 N (12.64–14.48 kgf,
27.88–31.92 lbf)
Spring tilt (intake) 2.5 °/1.8 mm (2.5 °/0.07 in)
Spring tilt (exhaust) 2.5 °/1.6 mm (2.5 °/0.06 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder
Bore 97.000–97.010 mm (3.8189–3.8193 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in)
Limit 0.15 mm (0.006 in)
Diameter 96.955–96.970 mm (3.8171–3.8177 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Offset 0.00 mm (0.0000 in)
Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in)
Limit 18.045 mm (0.7104 in)
Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in)
Limit 17.971 mm (0.7075 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B  T) 1.00  3.30 mm (0.04  0.13 in)
End gap (installed) 0.20–0.30 mm (0.0079–0.0118 in)
Limit 0.55 mm (0.0217 in)
Ring side clearance 0.015–0.065 mm (0.0006–0.0026 in)
Limit 0.120 mm (0.0047 in)
2nd ring
Ring type Taper
Dimensions (B  T) 1.00  3.10 mm (0.04  0.12 in)
End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in)
Limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.060 mm (0.0008–0.0024 in)
Limit 0.120 mm (0.0047 in)
Oil ring
Dimensions (B  T) 1.50  2.55 mm (0.06  0.10 in)
End gap (installed) 0.20–0.50 mm (0.0079–0.0197 in)

ENGINE SPECIFICATIONS
2-5
Crankshaft
Crank assembly width 61.95–62.00 mm (2.439–2.441 in)
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.150–0.450 mm (0.0059–0.0177 in)
Balancer
Balancer drive method Gear
Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 7.0–12.0 mm (0.28–0.47 in)
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.85 mm (0.112 in)
Plate quantity 8 pcs
Clutch plate thickness 1.50–1.70 mm (0.059–0.067 in)
Plate quantity 7 pcs
Warpage limit 0.10 mm (0.0039 in)
Clutch spring free length 48.00 mm (1.89 in)
Limit 45.60 mm (1.80 in)
Spring quantity 6 pcs
Push rod bending limit 0.10 mm (0.0039 in)
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Spur gear
Primary reduction ratio 2.609 (60/23)
Final drive Chain
Secondary reduction ratio 3.692 (48/13)
Operation Left foot operation
Gear ratio
1st 1.929 (27/14)
2nd 1.533 (23/15)
3rd 1.300 (26/20)
4th 1.091 (24/22)
5th 0.952 (20/21)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork guide bar bending limit 0.050 mm (0.0020 in)
Shift fork thickness 4.85 mm (0.1909 in)
Decompression device
Device type Auto decomp
Air filter
Air filter element Wet element
Air filter oil grade Foam air-filter oil
Fuel pump
Pump type Electrical
Fuel injector
Model/quantity 1010/1
Resistance 12.0 

ENGINE SPECIFICATIONS
2-6
Throttle body
Type/quantity 30RA-JX1A/1
ID mark 1SL5 10
Fuel line pressure at idling 324.0 kPa (3.24 kgf/cm
2, 47.0 psi)
Throttle position sensor
Resistance 6.30 k
Output voltage (at idle) 0.48–0.52 V
Fuel injection sensor
Crankshaft position sensor resistance 228–342 
Intake air pressure sensor output voltage 3.57–3.71 V at 101.3 kPa
Intake air temperature sensor resistance 290–390  at 80 °C (176 °F)
Coolant temperature sensor resistance 2.51–2.78 k at 20°C (68°F) 210–221  at
100°C (212°F)
Idling condition
Engine idling speed 1900–2100 r/min
CO% 6.8–9.2 %
Intake vacuum 30.5–37.8 kPa (229–284 mmHg,
9.0–11.2 inHg)
Water temperature 70–80 °C (158–176 °F)
Oil temperature 55–65 °C (131–149 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)

ELECTRICAL SPECIFICATIONS
2-11
EASB111054
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 B110/YAMAHA (USA) (CAN)
B111/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
Spark plug cap
Resistance 10.00 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
EASB111056ENGINE 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)
E
LT
M
LT
LT
LT

TIGHTENING TORQUES
2-14
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

LUBRICATION POINTS AND LUBRICANT TYPES
2-20
EASB111058
LUBRICATION POINTS AND LUBRICANT TYPES
EASB111059ENGINE
Lubrication point Lubricant types
Oil seal lips
Bearing
O-ring
Camshaft cap bolt threads and contacting surface
Cylinder head bolt threads, seats, washers
Valve stems
Valve stem ends
Valve lifter outer surface
Camshaft lobe and journal
Valve lifter top surface
Crankshaft journal
Crankshaft big end thrust surfaces
Piston outer surface
Piston pin outer surface
Decompression system moving parts
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil passage gasket
Oil pump shaft
Kick gear and ratchet wheel
Kick shaft
Kick idle gear inner surface
Ratchet wheel and ratchet wheel guide contacting portion
Primary drive gear nut threads and contacting surface
Clutch boss nut threads and contacting surface
Primary driven gear inner surface and end surface
Clutch push rod washer
Clutch push rod 1 outer surface
Clutch push rod 1 thrust surface
Clutch push rod 2 outer surface
Push lever shaft outer surface
Transmission gear inner surface (wheel and pinion) and collar
Transmission gears (shift fork groove)
Shift cam grooves
Shift fork and shift fork guide outer surface
Shift shaft and collar
Shift lever assembly moving parts
LS
E
LS
E
M
M
M
E
M
E
M
E
E
M
E
E
E
LS
E
M
E
E
M
E
E
E
E
E
E
E
E
M
E
E
E
E
E

3
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS.......................................................................... 3-1
MAINTENANCE INTERVALS .................................................................... 3-1
PRE-OPERATION INSPECTION AND MAINTENANCE................................. 3-7
GENERAL INSPECTION AND MAINTENANCE........................................ 3-7
ENGINE............................................................................................................ 3-8
CHECKING THE COOLANT LEVEL .......................................................... 3-8
CHECKING THE COOLING SYSTEM ....................................................... 3-8
CHANGING THE COOLANT...................................................................... 3-8
CHECKING THE RADIATOR CAP ............................................................ 3-9
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ......... 3-9
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-10
ADJUSTING THE CLUTCH LEVER POSITION ...................................... 3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-11
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-11
LUBRICATING THE THROTTLE CABLE ................................................ 3-12
CLEANING THE AIR FILTER ELEMENT................................................. 3-12
CHECKING THE THROTTLE BODY JOINT ............................................ 3-13
CHECKING THE BREATHER HOSES .................................................... 3-13
CHECKING THE EXHAUST SYSTEM..................................................... 3-14
CHECKING THE FUEL LINE ................................................................... 3-14
CHECKING THE ENGINE OIL LEVEL..................................................... 3-14
CHANGING THE ENGINE OIL ................................................................ 3-15
ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-16
ADJUSTING THE VALVE CLEARANCE ................................................. 3-17
CHASSIS........................................................................................................ 3-22
BLEEDING THE BRAKE SYSTEM .......................................................... 3-22
CHECKING THE BRAKE HOSE .............................................................. 3-23
ADJUSTING THE FRONT BRAKE .......................................................... 3-23
ADJUSTING THE REAR BRAKE ............................................................. 3-24
CHECKING THE FRONT BRAKE PADS ................................................. 3-24
CHECKING THE REAR BRAKE PADS ................................................... 3-26
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-27
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-27
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-28
CHECKING THE FRONT FORK LEGS ................................................... 3-29
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-29
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................ 3-29
AIR BLEEDING FROM FRONT FORK .................................................... 3-30
ADJUSTING THE FRONT FORK LEGS .................................................. 3-30
CHECKING THE SWINGARM OPERATION ........................................... 3-31
CHECKING THE REAR SUSPENSION ................................................... 3-31
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-31
CHECKING THE TIRES ........................................................................... 3-34
CHECKING AND TIGHTENING THE SPOKES ....................................... 3-34
CHECKING THE WHEELS ...................................................................... 3-34

MAINTENANCE INTERVALS
3-2
PISTON RING
Inspect Check the end gap of the pis-
ton ring.
Replace Replace the piston, piston pin,
piston pin clip, and piston ring
all as a set.
PISTON PIN
Inspect
Replace Replace the piston, piston pin,
piston pin clip, and piston ring
all as a set.
CYLINDER HEAD Check the coolant passages
for corrosion.
Inspect carbon deposits and
eliminate them.
Inspect and clean Check for warpage, and re-
place the gasket.
CYLINDER
Inspect and clean Inspect score marks.
Replace Inspect wear.
ENGINE OIL
Inspect Check the engine oil amount.
Replace
OIL FILTER ELE-
MENT
Replace
OIL STRAINER
Clean
CLUTCH
Inspect and adjust Inspect housing, friction plate,
clutch plate and spring.
Replace
TRANSMISSION
Inspect
Replace bearings
SHIFT FORK, SHIFT
CAM, GUIDE BAR
Inspect Inspect wear.ITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks

MAINTENANCE INTERVALS
3-3
NUT (ROTOR)
Retighten Check for tightening torques.
EXHAUST PIPE, SI-
LENCER, PROTEC-
TOR
Inspect and re-
tightenCheck for exhaust leaks, and
tightening torques.
Clean
Replace fiver ** When the exhaust sound be-
comes louder or when a per-
formance drop is felt.
CRANKSHAFT
Inspect and clean
THROTTLE BODY
Inspect
AIR FILTER
Clean and lubri-
cateUse foam air-filter oil or equiv-
alent oil.
Replace
SPARK PLUG
Inspect and clean Check the electrodes and the
terminals for wear.
Replace
COOLING SYSTEM
Check coolant lev-
el and leakage
Check radiator cap
operationUse the radiator cap tester for
a checkup.
Check radiator cap
attached
Change the cool-
antEvery two years
Inspect hoses
ENGINE GUARD
Replace Breakage
FRAME
Clean and inspectITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks