2005 YAMAHA YZ450F oil

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ENGCRANKCASE AND CRANKSHAFT
Extent of removal Order Part name Q’ty Remarks
10 Crankcase (right) 1
Refer to “REMOVAL POINTS”.
11 Crankcase (left) 1
12 Oil strainer 1
13 Oil delivery pipe 2 1
14 Crankshaft 1 Use special tool.
Refer to “REMOVAL POINTS”.
2
1

4 - 87
ENGCRANKCASE AND CRANKSHAFT
CRANKCASE BEARING
Extent of removal:
1 Crankcase bearing removal
Extent of removal Order Part name Q’ty Remarks
CRANKCASE BEARING
REMOVAL
Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT
CAM AND SHIFT FORK” section.
Shift cam and shift fork
1 Oil seal 3
2 Bearing 10 Refer to “REMOVAL POINTS”.
1

4 - 89
ENGCRANKCASE AND CRANKSHAFT
Crankshaft
1. Remove:
Crankshaft 1
Use the crankcase separating tool 2.
CAUTION:
Do not use a hammer to drive out the
crankshaft.
Crankshaft bearing
1. Remove:
Bearing 1
NOTE:
Remove the bearing from the crankcase by
pressing its inner race.
Do not use the removed bearing.
Crankcase separating tool:
YU-1135-A/90890-01135
INSPECTION
Timing chain and timing chain guide
1. Inspect:
Timing chain
Cracks/stiff → Replace the timing chain
and camshaft sprocket as a set.
2. Inspect:
Timing chain guide
Wear/damage → Replace.
EC4N4101
Crankcase
1. Inspect:
Contacting surface a
Scratches → Replace.
Engine mounting boss b, crankcase
Cracks/damage → Replace.
2. Inspect:
Bearing
Rotate inner race with a finger.
Rough spot/seizure → Replace.
3. Inspect:
Oil seal
Wear/damage → Replace.

4 - 90
ENGCRANKCASE AND CRANKSHAFT
EC4N4201
Crankshaft
1. Measure:
Runout limit a
Small end free play limit b
Connecting rod big end side clearance c
Crank width d
Out of specification → Replace.
Use the dial gauge and a thickness
gauge.
Dial gauge and stand:
YU-3097/90890-01252
Standard
Runout
limit:0.03 mm
(0.0012 in)0.05 mm
(0.002 in)
Small end
free play:0.4 ~ 1.0 mm
(0.016 ~ 0.039 in)2.0 mm
(0.08 in)
Side
clearance:0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Crack
width:61.95 ~ 62.00 mm
(2.439 ~ 2.441 in)—
Oil strainer
1. Inspect:
Oil strainer
Damage → Replace.
Oil delivery pipe 2
1. Inspect:
Oil delivery pipe 2
Cracks/damage → Replace.
Oil delivery pipe holes 1
Clogged → Blow out with compressed
air.

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ENGCRANKCASE AND CRANKSHAFT
NOTE:
Hold the connecting rod at top dead center
with one hand while turning the nut of the
installing tool with the other. Operate the
installing tool until the crankshaft bottoms
against the bearing.
Before installing the crankshaft, clean the
contacting surface of crankcase.
CAUTION:
Do not use a hammer to drive in the crank-
shaft.
2. Check:
Shifter operation
Transmission operation
Unsmooth operation → Repair.
3. Install:
Oil strainer 1
Bolt (oil strainer) 2
4. Apply:
Sealant
On the crankcase (right) 1.
NOTE:
Clean the contacting surface of crankcase (left
and right) before applying the sealant.
Quick gasket®:
ACC-QUICK-GS-KT
YAMAHA Bond No. 1215:
90890-85505
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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ENGCRANKCASE AND CRANKSHAFT
5. Install:
Dowel pin 1
O-ring 2
Crankcase (right)
To crankcase (left).
NOTE:
Fit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft ham-
mer.
When installing the crankcase, the connect-
ing rod should be positioned at TDC (top
dead center).
New
6. Tighten:
Hose guide 1
Clutch cable holder 2
Bolt (crankcase)
NOTE:
Tighten the crankcase tightening bolts in
stage, using a crisscross pattern.
7. Install:
Oil delivery pipe 2
O-ring
Bolt (oil delivery pipe 2)
8. Install:
Timing chain
Timing chain guide (rear)
Bolt (timing chain guide)
9. Remove:
Sealant
Forced out on the cylinder mating sur-
face.
10. Apply:
Engine oil
To the crank pin, bearing and oil delivery
hole.
11. Check:
Crankshaft and transmission operation.
Unsmooth operation → Repair.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

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ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H4801
Shift fork, shift cam and segment
1. Inspect:
Shift fork 1
Wear/damage/scratches → Replace.
2. Inspect:
Shift cam 1
Segment 2
Bend/wear/damage → Replace.
3. Check:
Shift fork movement
Unsmooth operation → Replace shift
fork.
NOTE:
For a malfunctioning shift fork, replace not only
the shift fork itself but the two gears each adja-
cent to the shift fork.
ASSEMBLY AND INSTALLATION
Transmission
1. Install:
Collar 1
4th pinion gear (20T) 2
3rd pinion gear (18T) 3
2nd pinion gear (16T) 4
To main axle 5.
NOTE:
Apply the molybdenum disulfide oil on the
inner and end surface of the idler gear and on
the inner surface of the sliding gear, then
install.

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ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
2. Install:
2nd wheel gear (25T) 1
Collar 2
3rd wheel gear (23T) 3
4th wheel gear (21T) 4
1st wheel gear (27T) 5
O-ring 6
To drive axle 7.
NOTE:
Apply the molybdenum disulfide oil on the
inner and end surface of the idler gear and
on the inner surface of the sliding gear, then
install.
Apply the lithium soap base grease on the O-
ring.
3. Install:
Plain washer 1
Circlip 2
NOTE:
Be sure the circlip sharp-edged corner a is
positioned opposite side to the plain washer
and gear b.
Install the circlip with its ends c settled
evenly on the spline crests.
cc
New
4. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
When installing the spacer into the crank-
case, pay careful attention to the crankcase
oil seal lip.