2006 YAMAHA YZ450F Owners Manual

2 - 24
SPEC
1Gasgeberzug
2Gasnehmerzug
3Kühlerschlauch 2
4Zündspule
5Schwingenarm-Halterung
6Zylinderkopf-Entlüftungsschlauch
ÈDie Gaszüge über den Kühlerschlauch 2 führen.
ÉDie Gaszüge über die Zündspule führen.
ÊDie Gaszüge mit den Klemmen so befestigen,
dass sie nicht gebogen sind, und dann unter die
Schwingenarm-Halterung führen.
ËDen Zylinderkopf-Entlüftungsschlauch so verle-
gen, dass er nicht die Zündspule berührt.
DIAGRAMME D’ACHEMINEMENT DES CABLES
KABELFÜHRUNGSDIAGRAMME
1Câble des gaz (tiré)
2Câble des gaz (retour)
3Durit de radiateur 2
4Bobine d’allumage
5Support du bras arrière
6Durit de mise à l’air de la culasse
ÈAcheminer les câbles des gaz vers la durit de radia-
teur 2.
ÉAcheminer les câbles des gaz à l’extérieur de la
bobine d’allumage.
ÊFixer les câbles des gaz à l’aide du collier à pince en
évitant de couder les câbles, puis les passer sous le
support du bras arrière.
ËAcheminer la durit de mise à l’air de la culasse de
façon à ce qu’elle ne soit pas en contact avec la
bobine d’allumage.

2 - 25
SPECCABLE ROUTING DIAGRAM
1Master cylinder
2Brake hose holder
3Brake hoseÈInstall the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the caliper.
ÉPass the brake hose into the
brake hose holders.
ÊIf the brake hose contacts the
spring (rear shock absorber),
correct its twist.
ËInstall the brake hose so that its
pipe portion directs as shown
and lightly touches the projec-
tion on the master cylinder.
2
31
1A ËÊ
È É
A

2 - 25
SPEC
1Hauptbremszylinder
2Bremsschlauch-Halterung
3Bremsschlauch
ÈDen Bremsschlauch so montieren, dass der
Metallstutzen am Schlauchende, wie abgebildet,
an der Nase des Bremssattels anliegt.
ÉDen Bremsschlauch durch die entsprechenden
Schlauchhalterungen führen.
ÊFalls der Bremsschlauch die Feder des Feder-
beins berührt, den Schlauch entsprechend
umbiegen.
ËDen Bremsschlauch so montieren, dass der
Metallstutzen am Schlauchende, wie abgebildet,
an der Nase des Hauptbremszylinders anliegt.
DIAGRAMME D’ACHEMINEMENT DES CABLES
KABELFÜHRUNGSDIAGRAMME
1Maître-cylindre
2Support de durit de frein
3Durit de frein
ÈMonter la durit de frein de manière que sa partie
tubulaire soit orientée comme sur l’illustration et tou-
che légèrement la saillie de l’étrier de frein.
ÉAcheminer la durit de frein dans les supports de durit
de frein.
ÊSi la durit de frein entre en contact avec le ressort
(amortisseur arrière), en corriger la torsion.
ËMonter la durit de frein de manière que sa partie
tubulaire soit orientée comme sur l’illustration et tou-
che légèrement la saillie du maître-cylindre.

2 - 26
SPECCABLE ROUTING DIAGRAM
1Throttle cable
2Clamp
3Hot starter cable
4Clutch cable
5“ENGINE STOP” button lead
6Cable guide
7Brake hose
8Hose guideÈFasten the “ENGINE STOP” button lead to the
handlebar.
ÉPass the clutch cable and hot starter cable
through the cable guide.
ÊPass the brake hose in front of the number plate.
ËPass the throttle cables through the cable guide.
ÌPass the clutch cable and hot starter cable
through the cable guide on the number plate.
A
B
C
A
B
C40˚± 10˚
40˚± 10˚
2
È3
2
5
4
2
3
5
6
Ë1
4
5
7
Ê
6
É
Ì
8

2 - 26
SPEC
1Gaszug
2Klemme
3Warmstartzug
4Kupplungszug
5Kabel des Motorstoppschalters “ENGINE STOP”
6Kabelführung
7Bremsschlauch
8Schlauchführung
ÈDas Kabel des Motorstoppschalters “ENGINE
STOP” am Lenker befestigen.
ÉDen Kupplungszug und den Warmstartzug
durch die Kabelführung führen.
ÊDen Bremsschlauch an der Vorderseite des
Nummernschildes entlang führen.
ËDie Gaszüge durch die Führung leiten.
ÌDen Kupplungszug und den Warmstartzug
durch die Kabelführung am Nummernschild füh-
ren.
DIAGRAMME D’ACHEMINEMENT DES CABLES
KABELFÜHRUNGSDIAGRAMME
1Câble des gaz
2Collier à pince
3Câble de starter à chaud
4Câble d’embrayage
5Fil du bouton “ENGINE STOP”
6Guide-câble
7Durit de frein
8Guide de durit
ÈFixer le fil du bouton “ENGINE STOP” au guidon.
ÉAcheminer le câble d’embrayage et le câble de starter
à chaud dans le guide-câble.
ÊAcheminer la durit de frein devant la plaque d’identi-
fication.
ËAcheminer les câbles des gaz dans le guide-câble.
ÌAcheminer le câble d’embrayage et le câble de starter
à chaud dans le guide-câble sur la plaque d’identifica-
tion.

3 - 1
INSP
ADJ
MAINTENANCE INTERVALS
EC300000
REGULAR INSPECTION AND ADJUSTMENTS
MAINTENANCE INTERVALS
The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind
that such factors as weather, terrain, geographical location, and individual usage will alter the
required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in
maintaining and lubricating your machine, consult your Yamaha dealer.
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
ENGINE OIL
Replace
VALVES
The engine must be cold.
Check the valve seats
and valve stems for wear. Check the valve clearances
Inspect
Replace
VALVE SPRINGS
Check the free length and
the tilt. Inspect
Replace
VALVE LIFTERS
Check for scratches and
wear. Inspect
Replace
CAMSHAFTS Inspect the camshaft sur-
face.
Inspect the decompres-
sion system Inspect
Replace
CAMSHAFT SPROCKETS
Check for wear on the
teeth and for damage. Inspect
Replace
PISTON
Inspect crack
Inspect carbon deposits
and eliminate them. Inspect
Clean
Replace
PISTON RING
Check ring end gap Inspect
Replace
PISTON PIN
Inspect
Replace
CYLINDER HEAD Inspect carbon deposits
and eliminate them.
Change gasket Inspect and clean
CYLINDER
Inspect and clean
Inspect score marks
Inspect wear
Replace
CLUTCH
Inspect housing, friction
plate, clutch plate and
spring Inspect and adjust
Replace
TRANSMISSION
Inspect
Replace bearing

3 - 2
INSP
ADJ
MAINTENANCE INTERVALS
SHIFT FORK, SHIFT CAM, GUIDE BAR
InspectInspect wear
ROTOR NUT
Retighten
MUFFLER
Inspect and retighten
Clean
Replace * Whichever comes first
CRANK
Inspect and clean
CARBURETOR
Inspect, adjust and clean
SPARK PLUG
Inspect and clean
Replace
DRIVE CHAIN
Use chain lube
Chain slack: 48 ~ 58 mm
(1.9 ~ 2.3 in) Lubricate, slack, alignment
Replace
COOLING SYSTEM
Check coolant level and leakage
Check radiator cap operation
Replace coolant Every two years
Inspect hoses
OUTSIDE NUTS AND BOLTS Refer to “STARTING
AND BREAK-IN” section
in the CHAPTER 1. Retighten
AIR FILTER
Use foam air-filter oil or
equivalent oil Clean and lubricate
Replace
OIL FILTER
Replace
FRAME
Clean and inspect
FUEL TANK, COCK
Clean and inspect
BRAKES
Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid Every one year
FRONT FORKS
Inspect and adjust
Replace oil Suspension oil “S1”
Replace oil sealItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks
3

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube Lithium base grease
PROTECTOR GUIDE
Replace
REAR SHOCK ABSORBER
(After
rain ride)
Inspect and adjust
LubeMolybdenum disulfide
grease
Replace spring seat Every one year
Retighten
CHAIN GUARD AND ROLLERS
Inspect
SWINGARM
Molybdenum disulfide
grease
Inspect, lube and retighten
RELAY ARM, CONNECTING ROD
Molybdenum disulfide
grease
Inspect, lube and retighten
STEERING HEAD
Inspect free play and retighten
Clean and lube Lithium base grease
Replace bearing
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate Lithium base grease
THROTTLE, CONTROL CABLE
Yamaha cable lube or
SAE 10W-30 motor oil Check routing and connection
Lubricate
HOT STARTER, CLUTCH LEVER
Inspect free playItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks