oil YAMAHA YZ450F 2016 User Guide

ENGINE SPECIFICATIONS
2-2
EASB111052
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 450 cm
3
Cylinder arrangement Single cylinder
Bore  stroke 97.0  60.8 mm (3.8  2.4 in)
Compression ratio 12.5:1
Starting system Kickstarter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-40, SAE 10W-50, SAE 15W-40,
SAE 20W-40 or SAE 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt)
With oil filter element replacement 0.69 L (0.73 US qt, 0.61 Imp.qt)
Without oil filter element replacement 0.67 L (0.71 US qt, 0.59 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.150 mm (0.0059 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.17 mm (0.0067 in)
Cooling system
Radiator (including all routes) 1.04 L (1.10 US qt, 0.92 Imp.qt)
Radiator capacity 0.57 L (0.60 US qt, 0.50 mp.qt)
Radiator cap valve opening pressure 108–137 kPa (1.08–1.37 kg/cm
2, 15.7–19.9
psi)
Radiator core
Width 112.6 mm (4.43 in)
Height 235.0 mm (9.25 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)
Manufacturer/model NGK/CR8E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)

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)

CHASSIS SPECIFICATIONS
2-8
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter  thickness 270  3.0 mm (10.6  0.12 in)
Brake disc 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)
Specified brake fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Brake pedal position 0.0 mm (0.00 in)
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 runout limit (as measured on wheel) 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)
Specified brake 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)
4.90 N/mm (0.50 kgf/mm, 27.98 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
Quantity 511.0 cm
3 (17.28 US.oz, 18.02 Imp.oz)

CHASSIS SPECIFICATIONS
2-9
Rebound damping adjusting positions
Minimum 20 clicks out*
Standard 11 clicks out*
Maximum Fully turned in
*With the adjuster fully turned in
Compression damping adjusting positions
Minimum 20 clicks out*
Standard 8 clicks out* (USA) (CAN)
16 clicks out* (EUR) (JPN) (AUS) (NZL) (ZAF)
Maximum Fully turned in
*With the adjuster 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 56.00 N/mm (5.71 kgf/mm, 319.76 lbf/in)
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 preload adjusting positions
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
Minimum 30 clicks out*
Standard 14 clicks out* (USA) (CAN)
12 clicks out* (EUR) (JPN) (AUS) (NZL) (ZAF)
Maximum Fully turned in
*With the adjuster fully turned in
Compression damping setting
(for fast compression damping)
Minimum 2 turns out*
Standard 1-1/4 turns out* (USA) (CAN)
1-3/8 turns out* (EUR) (JPN) (AUS) (NZL)
(ZAF)
Maximum Fully turned in
*With the adjuster fully turned in
Compression damping setting
(for slow compression damping)
Minimum 20 clicks out*
Standard 10 clicks out* (USA) (CAN)
12 clicks out* (EUR) (JPN) (AUS) (NZL) (ZAF)
Maximum Fully turned in
*With the adjuster fully turned 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)
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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
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TIGHTENING TORQUES
2-15
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 RemarksE
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