2004 YAMAHA YZ450F check engine

3 - 18
INSP
ADJIDLE SPEED ADJUSTMENT/
VALVE CLEARANCE ADJUSTMENT
EC35M021
IDLE SPEED ADJUSTMENT
1. Start the engine and thoroughly warm it
up.
2. Adjust:
Idle speed
VALVE CLEARANCE ADJUSTMENT
NOTE:
The valve clearance should be adjusted
when the engine is cool to the touch.
The piston must be at Top Dead Center
(T.D.C.) on compression stroke to check or
adjust the valve clearance.
1. Remove:
Seat
Fuel tank
Refer to “SEAT, FUEL TANK AND SIDE
COVERS” section in the CHAPTER 4.
2. Remove:
Carburetor
Refer to “CARBURETOR” section in
the CHAPTER 4.
Spark plug
Engine stay (upper)
Cylinder head cover
Refer to “CAMSHAFTS” section in the
CHAPTER 4. Adjustment steps:
Adjust the pilot screw.
Refer to “PILOT SCREW ADJUSTMENT”
section.
Turn the throttle stop screw 1 until the
engine runs at the lowest possible speed.
NOTE:
Using a digital engine tachometer for idle
speed adjustment, detect the engine idling
speed by bringing the sensing element c of
the engine tachometer close to the ignition
coil 2.
To increase idle speed →
Turn the throttle stop screw 1 in a.
To decrease idle speed →
Turn the throttle stop screw 1 out b.
Engine idling speed:
1,900 ~ 2,100 r/min
c2

3 - 32
INSP
ADJ
DRIVE CHAIN SLACK ADJUSTMENT
5. Install:
Drive chain 1
Joint 2
Master link clip 3
CAUTION:
Be sure to install the master link clip to the
direction as shown.
aTurning direction
6. Lubricate:
Drive chain
Drive chain lubricant:
SAE 10W-30 motor oil or suit-
able chain lubricants
New
DRIVE CHAIN SLACK ADJUSTMENT
1. Elevate the rear wheel by placing the
suitable stand under the engine.
2. Check:
Drive chain slack a
Above the seal guard installation bolt.
Out of specification → Adjust.
NOTE:
Before checking and/or adjusting, rotate the
rear wheel through several revolutions and
check the slack several times to find the tight-
est point. Check and/or adjust chain slack with
rear wheel in this “tight chain” position.
Drive chain slack:
40 ~ 50 mm (1.6 ~ 2.0 in)

3 - 42
INSP
ADJ
STEERING HEAD INSPECTION AND ADJUSTMENT
2. Inspect:
Bearing free play
Exist play → Replace.
STEERING HEAD INSPECTION AND
ADJUSTMENT
1. Elevate the front wheel by placing a suit-
able stand under the engine.
2. Check:
Steering shaft
Grasp the bottom of the forks and gen-
tly rock the fork assembly back and
forth.
Free play → Adjust steering head.
3. Check:
Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action → Adjust steering ring
nut.
4. Adjust:
Steering ring nut
Steering ring nut adjustment steps:
Remove the number plate.
Remove the handlebar and handle crown.
Loosen the ring nut 1 using the ring nut
wrench 2.
Ring nut wrench:
YU-33975/90890-01403

3 - 45
INSP
ADJ
ELECTRICAL/SPARK PLUG INSPECTION
EC370000
ELECTRICAL
EC371001
SPARK PLUG INSPECTION
1. Remove:
Spark plug
2. Inspect:
Electrode 1
Wear/damage → Replace.
Insulator color 2
Normal condition is a medium to light
tan color.
Distinctly different color → Check the
engine condition.
NOTE:
When the engine runs for many hours at low
speeds, the spark plug insulator will become
sooty, even if the engine and carburetor are in
good operating condition.
3. Measure:
Plug gap a
Use a wire gauge or thickness gauge.
Out of specification → Regap.
Spark plug gap:
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
4. Clean the plug with a spark plug cleaner
if necessary.
5. Tighten:
Spark plug
NOTE:
Before installing a spark plug, clean the gas-
ket surface and plug surface.
Finger-tighten a the spark plug before
torquing to specification b.
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)

3 - 46
INSP
ADJ
IGNITION TIMING CHECK
IGNITION TIMING CHECK
1. Remove:
Timing plug 1
2. Attach:
Timing light
To the ignition coil lead
(orange lead 1).
Timing light:
YM-33277-A/90890-03141
3. Adjust:
Engine idling speed
Refer to “IDLE SPEED ADJUST-
MENT”.
4. Check:
Ignition timing
Visually check the stationary pointer a
is within the firing range b on the rotor.
Incorrect firing range → Check rotor
and pickup assembly.
5. Install:
Timing plug

4 - 26
ENGCAMSHAFTS
Decompression system
1. Check:
Decompression system
Checking steps:
Check that the decompressor cam 1
moves smoothly.
Check that the decompressor lever pin 2
projects from the camshaft.
Timing chain tensioner
1. Check:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver 1
and wind the tensioner rod up fully
clockwise.
When releasing the screwdriver by
pressing lightly with fingers, make sure
that the tensioner rod will come out
smoothly.
If not, replace the tensioner assembly.
ASSEMBLY AND INSTALLATION
1. Install:
Exhaust camshaft 1
Intake camshaft 2
Installation steps:
Turn the crankshaft counterclockwise until
the “I” mark a on the rotor is aligned with
the stationary pointer b on the crankcase
cover.
NOTE:
Apply the molybdenum disulfide oil on the
camshafts.
Apply the engine oil on the decompression
system.

4 - 67
ENGOIL PUMP
INSPECTION
Oil pump
1. Inspect:
Oil pump drive gear
Oil pump driven gear
Rotor housing
Oil pump cover
Cracks/wear/damage → Replace.
2. Measure:
Tip clearance a
Between the inner rotor 1 and the
outer rotor 2.
Tip clearance b
Between the outer rotor 2 and the rotor
housing 3.
Out of specification → Replace the oil
pump.
Tip clearance a:
0.12 mm or less
(0.0047 in or less)
: 0.20 mm (0.008 in)
Tip clearance b:
0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in)
: 0.24 mm (0.009 in)
Side clearance c:
0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in)
: 0.17 mm (0.007 in)
3. Check:
Unsmooth → Repeat steps #1 and #2
or replace the defective parts.
ASSEMBLY AND INSTALLATION
Oil pump
1. Install:
Oil pump drive shaft 1
Washer 2
Pin 3
Inner rotor 1 4
NOTE:
Apply the engine oil on the oil pump drive
shaft and inner rotor 1.
Fit the pin into the groove in the inner rotor 1.

4 - 88
ENGCRANKCASE AND CRANKSHAFT
REMOVAL POINTS
Crankcase
1. Separate:
Crankcase (right)
Crankcase (left)
Separation steps:
Remove the crankcase bolts, hose guide
and clutch cable holder.
NOTE:
Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove
them.
Remove the crankcase (right).
NOTE:
Place the crankcase with its left side
downward and split it by inserting a screw-
driver tip into the splitting slit a in the
crankcase.
Lift the crankcase (right) horizontally while
lightly patting the case splitting slit and
engine mounting boss using a soft ham-
mer, and leave the crankshaft and trans-
mission with the crankcase (left).
CAUTION:
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case.
Do not tap on gasket mating surface.
Work slowly and carefully. Make sure the
case halves separate evenly. If one end
“hangs up”, take pressure off the push
screw, realign, and start over. If the
cases do not separate, check for a
remaining case screw or fitting. Do not
force.
Remove the dowel pins and O-ring.
a