2005 YAMAHA YZ450F transmission

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS ..................................4-1
EXHAUST PIPE AND SILENCER .............4-3
RADIATOR ................................................4-5
CARBURETOR ..........................................4-8
CAMSHAFTS ...........................................4-21
CYLINDER HEAD ....................................4-29
VALVES AND VALVE SPRINGS ............4-33
CYLINDER AND PISTON ........................4-42
CLUTCH ...................................................4-48
OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT) .....4-55
BALANCER .............................................4-62
OIL PUMP ................................................4-65
KICK AXLE AND SHIFT SHAFT .............4-69
CDI MAGNETO ........................................4-76
ENGINE REMOVAL .................................4-80
CRANKCASE AND CRANKSHAFT ........4-85
TRANSMISSION, SHIFT CAM
AND SHIFT FORK ...................................4-94
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL .......5-1
FRONT BRAKE AND REAR BRAKE .....5-10
FRONT FORK ..........................................5-26
HANDLEBAR ...........................................5-42
STEERING ...............................................5-48
SWINGARM .............................................5-53
REAR SHOCK ABSORBER ....................5-61

GEN
INFO
ALLGEMEINE ANGABEN
FAHRZEUGBESCHREIBUNG
1Kupplungshebel
2Warmstarthebel
3Handbremshebel
4Gasdrehgriff
5Kühlerverschlußdeckel
6Tankverschluß
7Motorstoppschalter “ENGINE STOP”
8Kickstarterhebel
9Kraftstofftank
0Kühler
AKühlflüssigkeits-Ablaßschraube
BFußbremshebel
CVentilverbindung
DKraftstoffhahn
EChokehebel
FAntriebskette
GLuftfilter
HFußschalthebel
IÖlmeßstab
JTeleskopgabel
HINWEIS:
 Die Abbildungen in vorliegender Anleitung
können leicht vom eigentlichen Modell
abweichen und dienen daher lediglich zur
Bezugnahme.
 Änderungen an Design und technischen
Daten jederzeit vorbehalten.
DESCRIPTION
FAHRZEUGBESCHREIBUNG
RENSEIGNEMENTS
GENERAUX
DESCRIPTION
1Levier d’embrayage
2Levier de démarrage à chaud
3Levier de frein avant
4Poignée des gaz
5Bouchon de radiateur
6Bouchon de réservoir de carburant
7Bouton “ENGINE STOP”
8Kick
9Réservoir de carburant
0Radiateur
ABoulon de vidange du liquide de refroidissement
BPédale de frein arrière
CClapet de reniflard
DRobinet de carburant
ECommande de départ à froid
FChaîne de transmission
GFiltre à air
HSélecteur
IJauge d’huile
JFourche
N.B.:
 Votre moto diffère peut-être partiellement de
celle montrée sur ces photos.
 La conception et les caractéristiques peuvent être
modifiées sans préavis.
1 - 1
1

1 - 10
GEN
INFO
CONTROL FUNCTIONS
EC150000
CONTROL FUNCTIONS
EC151000
“ENGINE STOP” BUTTON
The “ENGINE STOP” button 1 is located on
the left handlebar. Continue pushing the
“ENGINE STOP” button till the engine comes
to a stop.
EC152000
CLUTCH LEVER
The clutch lever 1 is located on the left han-
dlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disen-
gage the clutch, and release the lever to
engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
EC153000
SHIFT PEDAL
The gear ratios of the constant-mesh 4 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.
EC154000
KICK STARTER
Rotate the kick starter 1 away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kick starter so the engine can be
started in any gear if the clutch is disengaged.
In normal practices, however, shift to neutral
before starting.
1
EC155001
THROTTLE GRIP
The throttle grip 1 is located on the right han-
dlebar; it accelerates or decelerates the
engine. For acceleration, turn the grip toward
you; for deceleration, turn it away from you.

1 - 14
GEN
INFO
STARTING AND BREAK-IN
STARTING AND BREAK-IN
WARNING
Never start or run the engine in a closed
area. The exhaust fumes are poisonous;
they can cause loss of consciousness and
death in a very short time. Always operate
the machine in a well-ventilated area.
CAUTION:
The carburetor on this machine has a
built-in accelerator pump. Therefore,
when starting the engine, do not operate
the throttle or the spark plug will foul.
Unlike a two-stroke engine, this engine
cannot be kick started when the throttle is
open because the kick starter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the
engine to start.
Before starting the machine, perform the
checks in the pre-operation check list.
STARTING A COLD ENGINE
1. Inspect the coolant level.
2. Turn the fuel cock to “ON”.
3. Shift the transmission into neutral.
4. Fully open the cold starter knob 1.
5. Kick the kick starter.
WARNING
Do not open the throttle while kicking the
kick starter. Otherwise, the kick starter may
kick back.

1 - 19
GEN
INFO
CLEANING AND STORAGE
EC1B0000
CLEANING AND STORAGE
EC1B1000
CLEANING
Frequent cleaning of your machine will
enhance its appearance, maintain good overall
performance, and extend the life of many com-
ponents.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprock-
ets, or wheel axles.
3. Rinse the dirt and degreaser off with a gar-
den hose; use only enough pressure to do
the job.
CAUTION:
Excessive hose pressure may cause water
seepage and contamination of wheel bear-
ings, front forks, brakes and transmission
seals. Many expensive repair bills have
resulted from improper high pressure
detergent applications such as those avail-
able in coin-operated car washers.
4. After the majority of the dirt has been
hosed off, wash all surfaces with warm
water and a mild detergent. Use an old
toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel
and lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery
cleaner to keep the cover pliable and
glossy.

GEN
INFO
8. Alle lackierten und verchromten Oberflä-
chen mit Pflegewachs behandeln. Keine
Pflegemittel mit Scheurmitteln verwenden,
um Kratzer zu vermeiden.
9. Anschließend den Motor anlassen und
einige Minuten lang betreiben.
LAGERUNG
Soll das Motorrad länger als 60 Tage gelagert
werden, sind gewisse Schutzmaßnahmen not-
wendig. Das Motorrad nach der Wäsche, wie
nachfolgend beschrieben, auf die Lagerung
vorbereiten.
1. Das Benzin aus dem Kraftstofftank ablas-
sen und den Vergaser entleeren.
2. Die Zündkerze herausdrehen, einen Eßlöf-
fel SAE 10W-30-Motoröl in die Zündker-
zenbohrung gießen und die Zündkerze
wieder eindrehen. Bei betätigtem Motor-
stoppschalter mehrmals den Kickstarterhe-
bel durchtreten, um die
Zylinderwandungen mit Öl zu bedecken.
3. Die Antriebskette abnehmen, gründlich rei-
nigen und anschließend schmieren. Die
Kette montieren oder in einem am Rahmen
angebundenen Plastikbeutel aufbewahren.
4. Sämtliche Seilzüge ölen.
5. Das Motorrad so abstützen, daß die Räder
sich frei drehen lassen.
6. Einen Plastikbeutel über die Schalldämp-
feröffnung binden, damit keine Feuchtigkeit
eindringt.
7. Ist der Lagerort feucht oder salzhaltig,
sämtliche Metallflächen mit Sprühöl behan-
deln. Öl von Gummiteilen und der Sitzbank
fernhalten.
HINWEIS:
Anfallende Reparaturen oder Inspektion vor
der Stillegung ausführen.
NETTOYAGE ET REMISAGE
PFLEGE UND LAGERUNG
8. Une cire pour carrosserie peut être utilisée pour
toutes les surfaces peintes et chromées. Ne pas
employer de cires détergentes car elles contien-
nent souvent des abrasifs.
9. Lorsque le nettoyage est terminé, mettre le
moteur en marche et le laisser tourner au ralenti
pendant plusieurs minutes.
REMISAGE
Si la moto doit être remisée pour 60 jours ou plus, il
convient de prendre certaines précautions pour évi-
ter tout endommagement. Après un nettoyage com-
plet de la moto, la préparer comme suit pour le
remisage:
1. Vidanger le réservoir de carburant, le circuit de
carburant et la cuve à niveau constant du carbu-
rateur.
2. Déposer la bougie, verser une cuillère à soupe
d’huile moteur SAE 10W-30 dans le trou de
bougie et replacer la bougie. Enfoncer le coupe-
circuit du moteur et lancer quelques fois le
moteur à l’aide du kick afin de répartir l’huile
sur les parois du cylindre.
3. Déposer la chaîne de transmission, la nettoyer
soigneusement à l’aide d’un solvant puis la
graisser. Remettre en place la chaîne ou la con-
server dans un sachet en plastique (attaché au
cadre pour éviter de l’égarer).
4. Lubrifier tous les câbles de commande.
5. Placer un support sous le cadre afin de suréle-
ver les deux roues.
6. Couvrir la sortie du tuyau d’échappement d’un
sachet en plastique pour empêcher la pénétra-
tion d’humidité.
7. Si la moto doit être remisée dans un lieu très
humide ou exposé à l’air marin, enduire toutes
les surfaces métalliques extérieures d’une fine
couche d’huile. Ne pas enduire d’huile les par-
ties en caoutchouc et la housse de selle.
N.B.:
Effectuer toutes les réparations nécessaires avant de
remiser la moto.
1 - 20

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 - 10 Item Standard
Lubrication chart:
Pressure feed
Splashed scavenge
Oil strainer
Oil pan Oil pump rotor 2
Oil pump rotor 1
Oil tank
Oil filter
Check ball
Cylinder head
Crank pinPiston pinPiston
Drive axleMain axleTransmission gears
Camshaft
Valve lifter
MAINTENANCE SPECIFICATIONS