2005 YAMAHA YZ450F ignition

CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS
AND WIRING DIAGRAM ...........................6-1
MAP-CONTROLLED CDI UNIT .................6-2
IGNITION SYSTEM ....................................6-3
TPS (THROTTLE POSITION SENSOR)
SYSTEM .....................................................6-7
CHAPTER 7
TUNING
ENGINE ......................................................7-1
CHASSIS .................................................7-11

GEN
INFO
1 - 8
SPECIAL TOOLS
YU-33975, 90890-01403 Ring nut wrench
This tool is used when tighten the steering ring nut to
specification.YU-33975 90890-01403
YM-01442, 90890-01442 Fork seal driver
This tool is used when install the fork oil seal.YM-01442 90890-01442
YM-01500, 90890-01500 Cap bolt wrench
This tool is used to loosen or tighten the base valve.YM-01500 90890-01500
YM-01501, 90890-01501 Cap bolt ring wrench
This tool is used to loosen or tighten the damper
assembly.YM-01501 90890-01501
YU-3112-C, 90890-03112 Pocket tester
Use this tool to inspect the coil resistance, output
voltage and amperage.YU-3112-C 90890-03112
YM-33277-A, 90890-03141 Timing light
This tool is necessary for checking ignition timing.YM-33277-A 90890-03141
YM-4019, 90890-04019 Valve spring compressor
This tool is needed to remove and install the valve
assemblies.YM-4019 90890-04019
YM-91042, 90890-04086 Clutch holding tool
This tool is used to hold the clutch when removing or
installing the clutch boss securing nut.YM-91042 90890-04086
YM-4116, 90890-04116
YM-4097, 90890-04097Valve guide remover
Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)
This tool is needed to remove and install the valve
guide.YM-4116
YM-409790890-04116
90890-04097
Part number Tool name/How to use Illustration

GEN
INFO
1 - 9
SPECIAL TOOLS
YM-4117, 90890-04117
YM-4098, 90890-04098Valve guide installer
Intake
Exhaust
This tool is needed to install the valve guide.YM-4117
YM-409890890-04117
90890-04098
YM-4118, 90890-04118
YM-4099, 90890-04099Valve guide reamer
Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)
This tool is needed to rebore the new valve guide.YM-4118
YM-4099 90890-04118
90890-04099
YM-34487
90890-06754Dynamic spark tester
Ignition checker
This instrument is necessary for checking the ignition
system components.YM-34487 90890-06754
ACC-QUICK-GS-KT
90890-85505Quick gasket

YAMAHA Bond No. 1215
This sealant (Bond) is used for crankcase mating sur-
face, etc.ACC-QUICK-GS-KT 90890-85505
Part number Tool name/How to use Illustration

SPEC
2 - 3 Transmission:
Primary reduction system Gear
Primary reduction ratio 61/23 (2.652)
Secondary reduction system Chain drive
Secondary reduction ratio 51/14 (3.643)
Transmission type Constant mesh, 4-speed
Operation Left foot operation
Gear ratio: 1st 27/14 (1.929)
2nd 25/16 (1.563)
3rd 23/18 (1.278)
4th 21/20 (1.050)
Chassis:
Frame type Semi double cradle
Caster angle 27.1°
Trail 116 mm (4.57 in) (For USA, ZA, AUS, NZ)
117 mm (4.61 in) (For EUROPE except F)
118 mm (4.65 in) (For F, CDN)
Tire:
Type With tube
Size (front) 80/100-21 51M (For USA, CDN, ZA, AUS, NZ
and F)
80/100-21 51R (For EUROPE except F)
Size (rear) 110/90-19 62M (For USA, CDN, ZA, AUS, NZ
and F)
110/90-19 NHS (For EUROPE except F)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto
GENERAL SPECIFICATIONS

SPEC
2 - 17
EC212300
ELECTRICAL
Item Standard Limit
Ignition system:
Advancer type Electrical ----
C.D.I.:
Magneto-model (stator)/manufacturer 5XD-00/YAMAHA ----
Source coil 1 resistance (color) 720 ~ 1,080 Ω at 20 °C (68 °F)
(Green – Brown)----
Source coil 2 resistance (color) 44 ~ 66 Ω at 20 °C (68 °F)
(Black – Pink)----
Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)
(White – Red)----
CDI unit-model/manufacturer 5XD-50/YAMAHA (For USA)
5XD-60/YAMAHA (Except for
USA)----
----
Ignition coil:
Model/manufacturer 5TA-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ----
Secondary winding resistance 4.6 ~ 6.8 kΩ at 20 °C (68 °F) ----
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 56 5.6 40
Neutral switch M5 × 0.8 2 4 0.4 2.9
MAINTENANCE SPECIFICATIONS

2 - 21
SPECCABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Oil tank breather hose
3Hot starter cable
4Radiator hose 4
5Clutch cable
6Cylinder head breather hose
7Radiator hose 1
8Hose guide
9Brake hose
0“ENGINE STOP” button lead
AClamp
BSub wire harness
CTPS (throttle position sensor)
lead
DNeutral switch lead
EOil hoseFRadiator breather hose
GCDI magneto lead
HCarburetor breather hose
IOverflow hose
ÈInsert the end of the fuel tank
breather hose into the hole in
the steering shaft cap.
ÉPass the hot starter cable
between the cylinder head
breather hose, oil tank breather
hose and ignition coil, then on
the outside of the left engine
bracket.
ÊPass the clutch cable through
the cable guides.ËPass the cylinder head breather
hose on the outside of the radia-
tor hose 1 and on the inside of
the radiator pipe (radiator hose
4).
ÌPass the clutch cable in front of
the lower radiator mounting boss.
ÍFasten the “ENGINE STOP” but-
ton lead and sub wire harness to
the frame at the protecting tube
of the sub wire harness with a
plastic locking tie and cut off the
tie end.
B
0
C-C
D-D
B
A
AB
DD
CC
F
D G
F
D
A
G
A
A
F
AE
A
DC A A A A B A 0
1
2
3
4 5 6 7 89
Ì
Ë
ÊÉ ÈÙÍ
Î
Ï
Ð
Ð Ñ
A
Ô Õ Ø
Ú HIH
E Û
Ò
Ö ×
Ê Ê Ê
Ó

2 - 24
SPECCABLE ROUTING DIAGRAM
1CDI unit
2Hot starter cable
3Throttle cable (return)
4Throttle cable (pull)
5Ignition coil
6Radiator breather hose
7Radiator hose 4
8Cylinder head breather hose
9CDI unit bracket
0CDI unit bandÈPass the hot starter cable and
throttle cables through the cable
guides.
ÉPass the hot starter cable over
the top radiator mounting boss.
ÊPass the hot starter cable and
throttle cables between the radi-
ator and frame, then over the
middle radiator mounting boss.
ËPass the throttle cables on the
outside of the ignition coil.
ÌPass the carburetor breather
hose (throttle cable cover)
through the hose holder.
ÍPass the radiator breather hose
at the rear of the radiator, on the
left of the chassis, and then
between the frame and radiator
hose 4.ÎInsert the CDI unit band over the
CDI unit bracket as far as possi-
ble.
ÏFirst install the CDI unit and CDI
unit band to the CDI unit
bracket, then the CDI unit
bracket to the frame.
8
761
09
12
3
4 ÍB
A
A
B
Î
Ï
É
ÌÈ
Ê
Ë
5

3 - 4
INSP
ADJ
PRE-OPERATION INSPECTION AND MAINTENANCE
EC320000
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page
CoolantCheck that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.P.3-5 ~ 9
FuelCheck that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.P.1-13
Engine oilCheck that the oil level is correct. Check the crankcase and
frame oil line for leakage.P.3-13 ~ 17
Gear shifter and clutchCheck that gears can be shifted correctly in order and that the
clutch operates smoothly.P.3-9
Throttle grip/HousingCheck that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.P.3-10
Brakes Check the play of front brake and effect of front and rear brake. P.3-24 ~ 30
ChainCheck chain slack and alignment. Check that the chain is lubri-
cated properly.P.3-31 ~ 33
WheelsCheck for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.P.3-41 ~ 42
SteeringCheck that the handlebar can be turned smoothly and have no
excessive play.P.3-42 ~ 44
Front forks and rear shock
absorberCheck that they operate smoothly and there is no oil leakage. P.3-33 ~ 40
Cables (wires)Check that the clutch and throttle cables move smoothly. Check
that they are not caught when the handlebars are turned or
when the front forks travel up and down.—
Muffler Check that the muffler is tightly mounted and has no cracks.—
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-31
Lubrication Check for smooth operation. Lubricate if necessary. P.3-45
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18
Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil are con-
nected tightly.P.1-6
SettingsIs the machine set suitably for the condition of the racing course
and weather or by taking into account the results of test runs
before racing? Are inspection and maintenance completely
done?P.7-1 ~ 21