2005 YAMAHA YZ450F clock

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ENGCAMSHAFTS
Fit the timing chain 3 onto both camshaft
sprockets and install the camshafts on the
cylinder head.
NOTE:
The camshafts should be installed onto the
cylinder head so that the exhaust cam
sprocket punch mark c and the intake cam
sprocket punch mark d align with the sur-
face of the cylinder head.
CAUTION:
Do not turn the crankshaft during the
camshaft installation. Damage or
improper valve timing will result.
Install the clips and camshaft caps 4.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m  kg, 7.2 ft  lb)
NOTE:
Apply the engine oil on the thread and
contact surface of the bolts (camshaft cap)
5.
Tighten the bolts (camshaft cap) in a criss-
cross pattern.
CAUTION:
The bolts (camshaft cap) must be tight-
ened evenly, or damage to the cylinder
head, camshaft caps, and camshaft will
result.
5
4
E
2. Install:
Timing chain tensioner
Installation steps:
While pressing the tensioner rod lightly
with fingers, use a thin screwdriver and
wind the tensioner rod up fully clockwise.

4 - 28
ENG
With the rod fully wound and the chain ten-
sioner UP mark a facing upward, install
the gasket 1 and the chain tensioner 2,
and tighten the bolt 3 to the specified
torque.
T R..
Bolt (timing chain tensioner):
10 Nm (1.0 m  kg, 7.2 ft  lb)
Release the screwdriver, check the ten-
sioner rod to come out and tighten the
gasket 4 and the cap bolt 5 to the speci-
fied torque.
T R..
Tensioner cap bolt:
7 Nm (0.7 m  kg, 5.1 ft  lb)
5
4New
3. Turn:
Crankshaft
Counterclockwise several turns
4. Check:
Rotor “I” mark
Align with the crankcase stationary
pointer.
Camshaft match marks
Align with the cylinder head surface.
Out of alignment → Adjust.
CAMSHAFTS

4 - 71
ENGKICK AXLE AND SHIFT SHAFT
REMOVAL POINTS
EC4B3101
Kick axle assembly
1. Remove:
Kick axle assembly 1
NOTE:
Unhook the torsion spring 2 from the hole a
in the crankcase.
EC4C3101
Shift guide and shift lever assembly
1. Remove:
Bolt (shift guide)
Shift guide 1
Shift lever assembly 2
NOTE:
The shift lever assembly is disassembled at
the same time as the shift guide.
EC4N3100
Segment
1. Remove:
Bolt (segment) 1
Segment 2
NOTE:
Turn the segment counterclockwise until it
stops and loosen the bolt.
INSPECTION
EC4C4200
Kick axle and ratchet wheel
1. Check:
Ratchet wheel 1 smooth movement
Unsmooth movement → Replace.
Kick axle 2
Wear/damage → Replace.
Spring 3
Broken → Replace.
EC4C4300
Kick gear, kick idle gear and ratchet wheel
1. Inspect:
Kick gear 1
Kick idle gear 2
Ratchet wheel 3
Gear teeth a
Ratchet teeth b
Wear/damage → Replace.

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ENGKICK AXLE AND SHIFT SHAFT
3. Install:
Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove a in the spring guide fits on
the stopper of the torsion spring.
4. Install:
Kick axle assembly 1
Plain washer 2
NOTE:
Apply the molybdenum disulfide grease on
the contacting surfaces of the kick axle stop-
per a and ratchet wheel guide 3.
Apply the engine oil on the kick axle.
Slide the kick axle assembly into the crank-
case and make sure the kick axle stopper fits
into the ratchet wheel guide.
5. Hook:
Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook
into the proper hole a in the crankcase.
Kick idle gear
1. Install:
Kick idle gear 1
Plain washer 2
Circlip 3
NOTE:
Install the kick idle gear with its depressed
side a toward you.
Apply the engine oil on the kick idle gear
inner circumference.
New

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ENGCDI MAGNETO
EC4L3000
REMOVAL POINTS
EC4L3101
Rotor
1. Remove:
Nut (rotor) 1
Plain washer
Use the rotor holding tool 2.
2. Remove:
Rotor 1
Use the flywheel puller 2.
NOTE:
When installing the flywheel puller, turn it
counterclockwise.
Rotor holding tool:
YU-1235/90890-01235
Flywheel puller:
YM-1189/90890-01189
EC4L4000
INSPECTION
EC4L4101
CDI magneto
1. Inspect:
Rotor inner surface a
Stator outer surface b
Damage → Inspect the crankshaft runout
and crankshaft bearing.
If necessary, replace CDI magneto and/
or stator.
EC4L4200
Woodruff key
1. Inspect:
Woodruff key 1
Damage → Replace.

7 - 20
TUNSETTING
EC72H002
Suspension setting
Front fork
NOTE:
If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.
Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm
(3.5 ~ 3.9 in).
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff over entire rangeCompression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil amount Decrease oil amount by about 5 ~ 10 cm
3 (0.2 ~
0.4 Imp oz, 0.2 ~ 0.3 US oz).
Spring Replace with soft spring.
Unsmooth movement
over entire rangeOuter tube Check for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Inner tube
Slide metal Replace with a new one for extended use.
Piston metal Replace with a new one for extended use.
Under bracket tightening
torqueRetighten to specified torque.
Poor initial
movementRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Oil seal Apply grease in oil seal wall.
Soft over entire
range, bottoming outCompression damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Oil amount Increase oil amount by about 5 ~ 10 cm
3 (0.2 ~
0.4 Imp oz, 0.2 ~ 0.3 US oz).
Spring Replace with stiff spring.
Stiff toward stroke
endOil amountDecrease oil amount by about 5 cm
3 (0.2 Imp oz,
0.2 US oz).
Soft toward stroke
end, bottoming outOil amountIncrease oil amount by about 5 cm
3 (0.2 Imp oz,
0.2 US oz).
Stiff initial movement Compression dampingTurn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low front, tending to
lower front postureCompression damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when
one passenger is astride seat (lower rear posture).
Oil amount Increase oil amount by about 5 cm
3 (0.2 Imp oz,
0.2 US oz).
“Obtrusive” front,
tending to upper front
postureCompression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in)
when one passenger is astride seat (upper rear pos-
ture).
Spring Replace with soft spring.
Oil amount Decrease oil amount by about 5 ~ 10 cm
3 (0.2 ~
0.4 Imp oz, 0.2 ~ 0.3 US oz).

7 - 21
TUNSETTING
Rear shock absorber
NOTE:
If any of the following symptoms is experienced with the standard position as the base, make
resetting by reference to the adjustment procedure given in the same chart.
Adjust the rebound damping in 2-click increments or decrements.
Adjust the low compression damping in 1-click increments or decrements.
Adjust the high compression damping in 1/6 turn increments or decrements.
SymptomSection
Check Adjust
JumpLarge
gapMedium
gapSmall
gap
Stiff, tending to sinkRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in)
when one passenger is astride seat.
Spongy and unstableRebound damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Low compression damp-
ingTurn adjuster clockwise (about 1 click) to increase
damping.
Spring Replace with stiff spring.
Heavy and draggingRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Spring Replace with soft spring.
Poor road grippingRebound damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Low compression damp-
ingTurn adjuster clockwise (about 1 clicks) to increase
damping.
High compression damp-
ingTurn adjuster clockwise (about 1/6 clicks) to
increase damping.
Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in)
when one passenger is astride seat.
Spring Replace with soft spring.
Bottoming outHigh compression damp-
ingTurn adjuster clockwise (about 1/6 turn) to increase
damping.
Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in)
when one passenger in astride seat.
Spring Replace with stiff spring.
BouncingRebound damping Turn adjuster clockwise (about 2 clicks) to increase
damping.
Spring Replace with soft spring.
Stiff travelHigh compression damp-
ingTurn adjuster counterclockwise (about 1/6 turn) to
decrease damping.
Spring set length Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in)
when one passenger is astride seat.
Spring Replace with soft spring.