2005 YAMAHA YFZ450 clutch

8-8 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Engine oil filter element
Replace.Drive chain
Check and adjust slack/alignment/clean/lube.Front brake*Check free play/operation/fluid leakage/
See NOTE Page 8-9.
Correct if necessary.Rear brake*Check operation/fluid leakage/See NOTE Page 8-9.
Correct if necessary.Clutch*Check operation.
Adjust if necessary.Wheels*Check balance/damage/runout.
Replace if necessary.Wheel bearings*Check bearing assemblies for looseness/damage.
Replace if damaged.Steering system*Check operation.
Repair if damaged.
Check toe-in.
Adjust if necessary.Front and rear
suspension*Check operation.
Correct if necessary.Upper and lower arm
pivot and steering shaft*Lubricate every 6 months with lithium-soap-based grease.Rear arm pivot*
Lubricate every 6 months with lithium-soap-based grease.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U5TG61.book Page 8 Friday, April 2, 2004 11:28 AM

8-37
CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_14. Start the engine, and then let it idle for seve-
ral minutes while checking it for oil leakage. If
oil is leaking, immediately turn the engine off
and check for the cause.
15. Turn the engine off, and then check the oil
level and correct it if necessary.
16. Install the engine guard by installing the bolts,
and then tighten them to the specified torque.
U5TG61.book Page 37 Friday, April 2, 2004 11:28 AM

8-99 1. Adjusting nut c. Clutch lever free play
1.Écrou de réglage c. Jeu du levier d’embrayage
1. Tuerca de ajuste
c. Juego libre de la palanca del embrague
1. Locknut 2. Adjusting nut
1. Contre-écrou 2.Écrou de réglage
1. Contratuerca 2. Tuerca de ajuste
EBU14210
Clutch lever free play adjustment
The clutch lever free play should be adjusted to 8–
13 mm.
1. Fully turn the adjusting nut at the clutch lever
in direction
a to increase the free play or in
direction
b to decrease the free play.
If the specified free play cannot be obtained, pro-
ceed with the following steps.
2. Turn the adjusting nut at the clutch lever in di-
rection
a to loosen the cable.
3. Loosen the locknut at the crankcase side.
4. Turn the adjusting nut at the crankcase in di-
rection
a to increase the free play or in direc-
tion
b to decrease the free play.
5. Tighten the locknut at the crankcase side.
U5TG61.book Page 99 Friday, April 2, 2004 11:28 AM

8-113
EBU14020
Brake pedal, brake lever and clutch lever
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
U5TG61.book Page 113 Friday, April 2, 2004 11:28 AM

10-2
10
Engine oil:
Type
Recommended engine oil classification API Service SE, SF, SG type or higher
Quantity:
Without oil filter element replacement
With oil filter element replacement1.75 L
1.85 L MODEL YFZ450
-20˚ -10˚ 0˚
10˚20˚ 30˚40˚50˚C
10W/30
15W/4020W/4020W/50
10W/40
5W/30
CAUTION:In order to prevent clutch slippage (since the en-
gine oil also lubricates the clutch), do not mix any
chemical additives. Do not use oils with a diesel
specification of “CD” or oils of a higher quality
than specified. In addition, do not use oils labeled
“ENERGY CONSERVING II” or higher.
U5TG61.book Page 2 Friday, April 2, 2004 11:28 AM

10-3
Radiator capacity (including all routes): 1.30 L
Air filter: Wet element
Fuel:
Type
Tank capacity
Reserve amountPREMIUM UNLEADED GASOLINE ONLY
For Europe:
PREMIUM UNLEADED GASOLINE ONLY with
a research octane number of 97 or higher
10.0 L
1.9 L
Carburetor:
Type
× quantity
ManufacturerFCR39H
× 1
KEIHIN
Spark plug:
Type/manufacturer
GapCR8E/NGK
0.7–0.8 mm
Clutch:
Type
OperationWet, multiple-disc
Left hand operation
Transmission:
Primary Reduction System
Primary Reduction Ratio
Secondary Reduction System
Secondary Reduction Ratio
Transmission type
OperationSpur gear
62/22 (2.818)
Chain drive
38/14 (2.714)
Constant mesh, 5-speed forward
Left foot operation MODEL YFZ450
U5TG61.book Page 3 Friday, April 2, 2004 11:28 AM