2006 YAMAHA YZ450F light

4 - 28
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 molybdenum disulfide oil on the
thread of the bolts (camshaft cap) 5.
Tighten the bolts to the specified torque in
two or three steps in the proper tightening
sequence as shown.
CAUTION:
The bolts (camshaft cap) must be tight-
ened evenly, or damage to the cylinder
head, camshaft caps, and camshaft will
result.
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 - 39
ENGVALVES AND VALVE SPRINGS
9. Lap:
Valve face
Valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
Lapping steps:
Apply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.
Apply molybdenum disulfide oil to the
valve stem.
Install the valve into the cylinder head.
Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the compound.
NOTE:
For best lapping results, lightly tap the valve
seat while rotating the valve back and forth
between your hands.
Apply a fine lapping compound to the
valve face and repeat the above steps.
NOTE:
After every lapping operation be sure to
clean off all of the compound from the valve
face and valve seat.
Apply Mechanic’s blueing dye (Dykem) to
the valve face.
Install the valve into the cylinder head.
Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
Measure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.

4 - 41
ENGVALVES AND VALVE SPRINGS
ASSEMBLY AND INSTALLATION
1. Apply:
Molybdenum disulfide oil
Onto the valve stem and valve stem seal.
2. Install:
Valves 1
Valve spring seats 2
Valve stem seals 3
Valve springs 4
Valve spring retainers 5
NOTE:
Make sure that each valve is installed in its
original place, also referring to the painted
color as follows.
Intake (middle) a: blue
Intake (right/left) b: gray
Exhaust: not paint
Install the valve springs with the larger pitch
c facing upward.
dSmaller pitch
New
3. Install:
Valve cotters
NOTE:
While compressing the valve spring with a
valve spring compressor 1 install the valve
cotters.
4. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a piece of
wood.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
Valve spring compressor:
YM-4019/90890-04019

4 - 89
ENGCRANKCASE AND CRANKSHAFT
REMOVAL POINTS
Crankcase
1. Separate:
Crankcase (right)
Crankcase (left)
Separation steps:
Remove the crankcase bolts, hose guide
and clutch cable holder.
NOTE:
Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove
them.
Remove the crankcase (right).
NOTE:
Place the crankcase with its left side
downward and split it by inserting a screw-
driver tip into the splitting slit a in the
crankcase.
Lift the crankcase (right) horizontally while
lightly patting the case splitting slit and
engine mounting boss using a soft ham-
mer, and leave the crankshaft and trans-
mission with the crankcase (left).
CAUTION:
Use soft hammer to tap on the case half.
Tap only on reinforced portions of case.
Do not tap on gasket mating surface.
Work slowly and carefully. Make sure the
case halves separate evenly. If one end
“hangs up”, take pressure off the push
screw, realign, and start over. If the
cases do not separate, check for a
remaining case screw or fitting. Do not
force.
Remove the dowel pins and O-ring.
a
Balancer shaft
1. Remove:
Balancer shaft 1
NOTE:
Remove the balancer shaft with its flat side a
facing the crankshaft.

4 - 94
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:
Bolt (hose guide) 1
Bolt (crankcase)
NOTE:
Tighten the crankcase tightening bolts in
stage, using a crisscross pattern.
7. Install:
Timing chain
Timing chain guide (rear)
Bolt (timing chain guide)
8. Remove:
Sealant
Forced out on the cylinder mating sur-
face.
9. Apply:
Engine oil
To the crank pin, bearing and oil delivery
hole.
10. Check:
Crankshaft and transmission operation.
Unsmooth operation → Repair.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4 - 96
ENGTRANSMISSION, SHIFT CAM AND SHIFT FORK
EC4H3000
REMOVAL POINTS
EC4H3230
Transmission
1. Remove:
Main axle 1
Drive axle 2
Shift cam
Shift fork 3
Shift fork 2
Shift fork 1
NOTE:
Remove assembly with the collar 3 installed
to the crankcase.
Remove assembly carefully. Note the posi-
tion of each part. Pay particular attention to
the location and direction of shift forks.
Remove the main axle, drive axle, shift cam
and shift fork all together by tapping lightly on
the transmission drive axle with a soft ham-
mer.
EC4H4000
INSPECTION
EC4H4200
Gears
1. Inspect:
Matching dog a
Gear teeth b
Shift fork groove c
Wear/damage → Replace.
2. Inspect:
O-ring 1
Damage → Replace.
3. Check:
Gears movement
Unsmooth movement → Repair or
replace.
EC4H4600
Bearing
1. Inspect:
Bearing 1
Rotate inner race with a finger.
Rough spot/seizure → Replace.

5 - 21
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Brake lever 1
Bolt (brake lever) 2
Nut (brake lever) 3
NOTE:
Apply the lithium soap base grease on the
brake lever sliding surface, bolt and contacting
surface of the master cylinder piston.
Rear master cylinder
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the master
cylinder.
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
T R..6 Nm (0.6 m · kg, 4.3 ft · lb)
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
2. Install:
Master cylinder 1
Bolt (master cylinder) 2
3. Install:
Spring 1
Brake pedal 2
O-ring 3
Bolt (brake pedal) 4
Clip 5
NOTE:
Apply the lithium soap base grease on the bolt,
O-ring and brake pedal bracket.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)

5 - 22
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
Pin 1
Plain washer 2
Cotter pin 3
NOTE:
After installing, check the brake pedal height.
Refer to “REAR BRAKE ADJUSTMENT” sec-
tion in the CHAPTER 3.
New
Front brake hose
1. Install:
Copper washer 1
Brake hose 2
Union bolt 3
WARNING
Always use new copper washers.
CAUTION:
Install the brake hose so that its pipe por-
tion
a directs as shown and lightly
touches the projection
b on the caliper.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
2. Install:
Brake hose holder 1
Bolt (brake hose holder) 2
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
3. Install:
Brake hose holder 1
Nut (brake hose holder) 2
NOTE:
Align the top a of the brake hose holder with
the paint b of the brake hose.
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)