radiator YAMAHA YZ450F 2016 User Guide

PRE-OPERATION INSPECTION AND MAINTENANCE
3-7
EASB111066
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EASB111067GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.3-8 – 10
FuelCheck that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage.1-21
Engine oilCheck that the oil level is correct. Check the crank-
case and oil line for leakage.3-14 – 16
Gear shifter and clutchCheck that gears can be shifted correctly in order and
that the clutch operates smoothly.3-10 – 11
Throttle grip/HousingCheck that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary.3-11 – 12
BrakesCheck the play of front brake and effect of front and
rear brake.3-22 – 28
Drive chainCheck drive chain slack and alignment. Check that
the drive chain is lubricated properly.3-28 – 29
4-66 – 67
WheelsCheck for excessive wear and tire pressure. Check
for loose spokes and have no excessive play.3-34
SteeringCheck that the handlebar can be turned smoothly and
have no excessive play.3-35 – 36
Front forks and rear
shock absorberCheck that they operate smoothly and there is no oil
leakage.3-29 – 33
Cables (wires)Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.—
Exhaust pipeCheck that the exhaust pipe is tightly mounted and
has no cracks.3-14
Rear wheel sprocketCheck that the rear wheel sprocket tightening bolt is
not loose.4-8 – 9
Lubrication Check for smooth operation. Lubricate if necessary. 3-12, 3-36
Bolts and nutsCheck the chassis and engine for loose bolts and
nuts.1-24 – 25
Lead connectorsCheck that the AC magneto, ECU and ignition coil are
connected tightly.1-10 – 12
SettingsIs the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?10-1 – 8

ENGINE
3-8
EASB111068
ENGINE
EASB111069CHECKING THE COOLANT LEVELEWA1DX1003
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
1. Stand the vehicle upright on a level surface.
2. Remove:
• Radiator cap “1”
3. Check:
• Coolant level
Maximum level “a” or below  Add coolant
up to the maximum level.
ECA1DX1004
NOTICE
• Adding water instead of coolant lowers the
antifreeze content. If, therefore, water is
used instead of coolant, check, and if nec-
essary, adjust the antifreeze concentra-
tion.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
4. Start the engine, warm this up for several
minutes, and then stop it.
5. Check:
• Coolant level
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
EASB111070CHECKING THE COOLING SYSTEM
1. Remove:
• Seat
• Side cover (left/right)
• Air scoop (left/right)
Refer to “GENERAL CHASSIS” on page 4-
1.
• Air filter case cover
Refer to “THROTTLE BODY” on page 7-5.
2. Check:
• Radiator
• Radiator hoses
Crack/damage  Replace.
Refer to “RADIATOR” on page 6-1.
3. Install:
• Air filter case cover
Refer to “THROTTLE BODY” on page 7-5.
• Air scoop (left/right)
• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 4-
1.
EASB111071CHANGING THE COOLANTEWA1DX1004
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
1. Place a container under the engine.
2. Remove:
• Coolant drain bolt “1”
3. Remove:
• Radiator cap
Slowly loosen the radiator cap to drain cool-
ant.
TIP
When the radiator cap is loosened, coolant will
gush out transversely; therefore, bring the con-
tainer near to the outlet.
4. Thoroughly flush the cooling system with
clean tap water.
1. Radiator
1

ENGINE
3-9
5. Install:
• Copper washer
• Coolant drain bolt
6. Pour coolant.
EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a
doctor.
• If coolant splashes on your clothes, quick-
ly wash it away with water and then with
soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13480
NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water
is used instead of coolant check, and if
necessary, correct the antifreeze concen-
tration of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
• Do not mix different types of antifreeze.
7. Install:
• Radiator cap
8. Start the engine, warm this up for several
minutes, stop it, and then wait for it to cool
down.
9. Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-8.
EASB111072CHECKING THE RADIATOR CAP
1. Check:
• Seal (radiator cap) “1”
• Valve and valve seat “2”
Crack/damage  Replace.
Exist fur deposits  Clean or replace.
EASB111073CHECKING THE RADIATOR CAP VALVE
OPENING PRESSURE
1. Check:
• Radiator cap valve opening pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester adapter “2” and
the radiator cap tester “3” to the radiator cap
“1,” and activate the tester to check whether
it can stay for 5 to 10 seconds within stan-
dard pressure values.
TIP
Before attaching the cap to the tester, apply
water to its sealing surface.
No stay  Replace. Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Recommended coolant
High quality ethylene glycol
anti-freeze containing anti-cor-
rosion for aluminum engine
Radiator (including all routes)
1.04 L (1.10 US qt, 0.92 Imp.qt)
Coolant mixing ratio
1:1 (Coolant:Water)
New
T R..
Radiator cap valve opening pres-
sure
108–137 kPa (1.08–1.37 kg/cm
2,
15.7–19.9 psi)
Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984

ENGINE
3-10
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EASB111074CHECKING THE COOLANT CIRCULATORY
SYSTEM FOR LEAKS
1. Check:
• Coolant level
2. Install:
• Radiator cap tester “1”
• Adapter “2”
3. Activate the tester to apply the test pressure.
ECA@
NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylin-
der head gasket is replaced is made after 2
to 3 minutes of warm-up.
• Make sure that coolant is filled up to the
upper level beforehand.4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value  Correct.
• Radiator
• Radiator hose connections
Coolant leaks  Correct or replace.
• Radiator hoses
Bulges  Replace
EWA@
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
EASB111075ADJUSTING THE CLUTCH LEVER POSI-
TION
1. Adjust:
• Clutch lever position “a”
Loosen the locknut “1” and use the adjuster
“2” to adjust the clutch lever position “a” as
desired.
2. Tighten:
• Locknut Radiator cap tester
90890-01325
Mityvac cooling system tester kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
Test pressure value
196 kPa (1.96 kg/cm
2, 27.9 psi)
Locknut
4.8 Nm (0.48 m·kgf, 3.5 ft·lbf)
1
2
a
T R..

CYLINDER HEAD
5-20
EASB111213
CYLINDER HEAD
Removing the cylinder head
Order Part name Q’ty Remarks
Refer to “INSTALLING THE CYLINDER
HEAD” on page 5-23.
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.
Exhaust pipe and silencer Refer to “ENGINE REMOVAL” on page 5-1.
Radiator hose Disconnect.
Coolant temperature sensor coupler Disconnect.
Throttle body Refer to “THROTTLE BODY” on page 7-5.
Camshaft Refer to “CAMSHAFT” on page 5-12.
Upper engine bracket Refer to “ENGINE REMOVAL” on page 5-1.
1 Bolt (cylinder head) 2
2 Bolt (cylinder head) 4
3 Cylinder head 1
4 Cylinder head gasket 1
7 66
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
15 Nm (1.5 m kgf, 11 ft Ibf)T.R.
*
20 Nm (2.0 mkgf, 14 ftIbf)T.
R.
30 Nm (3.0 mkgf, 22 ftIbf)
*

CLUTCH
5-40
Removing the right crankcase cover
Order Part name Q’ty Remarks
Right engine guard Refer to “ENGINE REMOVAL” on page 5-1.
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-15.
CoolantDrain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-1.
Clutch cover Refer to “CLUTCH” on page 5-38.
1 Oil filter element cover 1
2 Oil filter element 1
3 Radiator pipe 2 1
4 Kickstarter lever 1
5 Right crankcase cover 1
6 Gaskets 1
7 Dowel pin 2
8Collar 1
For installation, reverse the removal proce-
dure.
T.R.
LS
New
New
67
2
5
4
1
7 8
New
3
LS
New
New
LS
LS
NewNew
LT
LS

6
COOLING SYSTEM
RADIATOR....................................................................................................... 6-1
HANDLING NOTE ...................................................................................... 6-3
CHECKING THE RADIATOR ..................................................................... 6-3
WATER PUMP.................................................................................................. 6-4
REMOVING THE OIL SEAL ....................................................................... 6-5
CHECKING THE WATER PUMP ............................................................... 6-5
CHECKING THE BEARING....................................................................... 6-5
INSTALLING THE OIL SEAL..................................................................... 6-5
ASSEMBLING THE WATER PUMP........................................................... 6-5

RADIATOR
6-1
EASB111293
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EASB111294
RADIATOR
Removing the radiator
Order Part name Q’ty Remarks
CoolantDrain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
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 Refer to “THROTTLE BODY” on page 7-5.
1 Radiator guard 2
2 Radiator hose clamp 8 Loosen.
3 Right radiator 1
11
12
New
New
New
LS
LS

RADIATOR
6-2
4 Radiator hose 2 1
5 Radiator hose 3 1
6 Radiator hose 4 1
7 Radiator pipe 2 1
8 Radiator breather hose 1
9 Left radiator 1
10 Radiator hose 1 1
11 Radiator pipe 1 1
12 Coolant temperature sensor 1
For installation, reverse the removal proce-
dure.
Removing the radiator
Order Part name Q’ty Remarks
11
12
New
New
New
LS
LS

RADIATOR
6-3
EASB111295HANDLING NOTEEWA
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
EASB111296CHECKING THE RADIATOR
1. Check:
• Radiator fins “1”
Obstructions  Clean.
Apply compressed air to the rear of the radi-
ator.
Damage  Repair or replace.
TIP
Correct any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• Radiator hoses
• Radiator pipes
Crack/damage  Replace.