clutch YAMAHA YZ450F 2016 Owner's Manual

GENERAL CHASSIS
4-2
EASB111118REMOVING THE LEFT SIDE COVER
1. Remove:
• Bolt (side cover)
• Side cover “1”
TIP
Draw the left side cover “1” backward to re-
move it because its projection “a” is inserted in
the rear frame.
EASB111119REMOVING THE SEAT
TIP
The fuel tank cap cover and the seat are cou-
pled with each other with a plastic band.
When removing the seat, always remove the
fuel tank cap cover beforehand.
1. Remove:
• Fuel tank cap cover “1”
Refer to “FUEL TANK CAP” on page 1-20.
2. Remove:
• Seat “1”
EASB111120REMOVING THE NUMBER PLATE
1. Remove:
• Bolt (number plate)
• Number plate “1”
TIP
• The projection “a” is inserted into the band of
the number plate. Pull the band off the projec-
tion before removal.
• Remove the clutch cable “2” from the cable
guide “b” on the number plate.
• The projection “c” on the lower bracket is in-
serted into the number plate. Remove the
number plate by pulling it off the projection.
1
a
1
1
1

HANDLEBAR
4-32
EASB111160
HANDLEBAR
Removing the handlebar
Order Part name Q’ty Remarks
Number plate Remove the band only.
1 Clutch cable 1 Disconnect.
2 Clutch lever holder 1
3 Engine stop switch 1
4 Launch control switch 1
5 Brake master cylinder 1
6 Throttle cable cap 1
7 Throttle cable (pull) 1 Disconnect.
8 Throttle cable (return) 1 Disconnect.
9 Right grip 1
10 Tube guide 1
11 Collars 1
12 Left grip 1
13 Handlebar upper holder 2

HANDLEBAR
4-35
3. Tighten:
• Lower handlebar holder nut
4. Install:
• Handlebar grip “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly coat the handlebar left end with a
rubber adhesive.
b. Install the handlebar grip on the handlebar
by pressing the grip from the left side.
c. Wipe off any excess adhesive with a clean
cloth.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Install the handlebar grip to the handlebar so
that the line “a” between the two arrow marks
faces straight upward.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Handlebar grip “1”
• Handlebar grip “2”
• Handlebar grip “3”
• Launch control switch “4”
•Clamp “5”
TIP
• The engine stop switch, the clutch lever, the
clutch lever holder and the launch control
switch should be installed according to the di-
mensions shown.
• Pass the engine stop switch lead through the
middle of the clutch lever holder.
6. Install:
• Right grip “1”
• Collar “2”
Apply adhesive to the tube guide “3”.
TIP
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface “a” with a lac-
quer thinner.
• Install the grip to the tube guide so that the
grip match mark “b” and tube guide slot “c”
form the angle as shown. Lower handlebar holder nut
40 Nm (4.0 m·kgf, 29 ft·lbf)
T R..
Engine stop switch screw
0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Clutch lever holder bolt
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Launch control switch screw
1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
T R..

HANDLEBAR
4-37
10.Install:
• Rubber cover “1”
• Cover (throttle cable housings) “2”
11.Install:
• Front brake master cylinder assembly “1”
• Front brake master cylinder holder “2”
• Bolt (brake master cylinder holder) “3”
TIP
• Install the brake master cylinder holder with
the “UP” mark facing up.
• Install in order for the top of the front brake
master cylinder assembly to be level.
• First, tighten the upper bolt, then the lower
bolt.
12.Install:
• Clutch cable “1”
TIP
Before installation, apply the lithium-soap-
based grease to the clutch cable end.13.Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LE-
VER FREE PLAY” on page 3-11.
14.Adjust:
• Throttle grip free play
Refer to “ADJUSTING THE THROTTLE
GRIP FREE PLAY” on page 3-11. Front brake master cylinder hold-
er bolt
9 Nm (0.9 m·kgf, 6.5 ft·lbf)
T R..
Clutch lever free play
7.0–12.0 mm (0.28–0.47 in)
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
1LS

CLUTCH......................................................................................................... 5-38
REMOVING THE CLUTCH ...................................................................... 5-41
CHECKING THE FRICTION PLATES...................................................... 5-41
CHECKING THE CLUTCH PLATES ........................................................ 5-41
CHECKING THE CLUTCH SPRINGS...................................................... 5-41
CHECKING THE CLUTCH HOUSING ..................................................... 5-42
CHECKING THE CLUTCH BOSS ............................................................ 5-42
CHECKING THE PRESSURE PLATE ..................................................... 5-42
CHECKING THE PUSH LEVER SHAFT .................................................. 5-42
CHECKING THE CLUTCH PUSH RODS ................................................ 5-42
CHECKING THE PRIMARY DRIVE GEAR .............................................. 5-42
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 5-43
INSTALLING THE OIL SEAL................................................................... 5-43
INSTALLING THE RIGHT CRANKCASE COVER ................................... 5-43
INSTALLING THE CLUTCH ..................................................................... 5-44
INSTALLING THE KICKSTARTER LEVER ............................................. 5-46
KICKSTATER................................................................................................. 5-47
REMOVING THE KICK SHAFT ASSEMBLY ........................................... 5-48
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 5-48
CHECKING THE KICK GEAR, KICK IDLE GEAR AND RATCHET
WHEEL .................................................................................................... 5-48
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 5-48
INSTALLING THE KICK IDLE GEAR ....................................................... 5-49
SHIFT SHAFT................................................................................................. 5-50
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 5-52
REMOVING THE SEGMENT ................................................................... 5-52
CHECKING THE SHIFT SHAFT .............................................................. 5-52
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 5-52
CHECKING THE STOPPER LEVER ....................................................... 5-52
INSTALLING THE STOPPER LEVER ..................................................... 5-53
INSTALLING THE SEGMENT.................................................................. 5-53
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 5-53
INSTALLING THE SHIFT SHAFT ............................................................ 5-54
INSTALLING THE SHIFT PEDAL ............................................................ 5-54
OIL PUMP AND BALANCER GEAR............................................................. 5-55
REMOVING THE BALANCER ................................................................. 5-57
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT
DRIVE GEAR, AND BALANCER WEIGHT GEAR .................................. 5-57
CHECKING THE BALANCER .................................................................. 5-57
CHECKING THE OIL PUMP .................................................................... 5-57
ASSEMBLING THE OIL PUMP ................................................................ 5-58
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 5-59

ENGINE REMOVAL
5-4
Removing the engine
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
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.
Rear fender 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.
Air filter case Refer to “THROTTLE BODY” on page 7-5.
Throttle body Refer to “THROTTLE BODY” on page 7-5.
Clutch cable Refer to “CLUTCH” on page 5-38.
Shift pedal Refer to “SHIFT SHAFT” on page 5-50.
1 Engine guard 1
2 Brake pedal 1
3Spring 1
4 Cylinder head breather hose 1

CLUTCH
5-38
EASB111231
CLUTCH
Removing the clutch
Order Part name Q’ty Remarks
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-15.
Brake pedal Refer to “ENGINE REMOVAL” on page 5-1.
1 Clutch cable 1 Disconnect.
2 Clutch cover 1
3 O-ring 1
4 Clutch spring 6
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8Washers 1
9 Bearing 1
10 Ball 1
11 Push rod 2 1
12 Friction plate 1 5
13 Clutch plate 7
LS
New
New
New
2
3 45
78961011
13
12
12
18
1
14
13
13
17
16
15
T.R.
T.R.
T.R.
T.R.
LT

CLUTCH
5-39
14 Friction plate 2 3 Identification color (purple)
15 Clutch boss 1
16 Thrust washer 1
17 Primary driven gear 1
18 Push lever shaft 1
For installation, reverse the removal proce-
dure.
Removing the clutch
Order Part name Q’ty Remarks
LS
New
New
New
2
3 45
78961011
13
12
12
18
1
14
13
13
17
16
15
T.R.
T.R.
T.R.
T.R.
LT

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

CLUTCH
5-41
EASB111232REMOVING THE CLUTCH
1. Remove:
• Clutch boss nut “1”
• Conical washer “2”
• Clutch boss “3”
TIP
While holding the clutch boss with the clutch
holder “4”, loosen the clutch boss nut.
EASB111233CHECKING THE FRICTION PLATES
1. Check:
• Friction plate
Damage/wear  Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
Out of specification  Replace the friction
plates as a set.
TIP
Measure it at four points on the friction plate.
EASB111234CHECKING THE CLUTCH PLATES
1. Check:
• Clutch plate
Damage  Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge
“1”)
Out of specification  Replace the clutch
plates as a set.
EASB111235CHECKING THE CLUTCH SPRINGS
1. Check:
• Clutch spring
Damage  Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length
Out of specification  Replace the clutch
springs as a set. Clutch holder
90890-04086
YM-91042
Friction plate thickness
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.85 mm (0.112 in)
34
12
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)