2006 YAMAHA YZ450F engine

2 - 22
SPEC
1Warmstartzug
2Klemme
3Drosselklappensensor-Kabel
4Buckel (Rahmen)
5Leerlaufschalter-Kabel
6Motorhalterung
7Motorschutzhalterung
8Lichtmaschinen-Kabel
9Kupplungszug
0Kühler-Entlüftungsschlauch
AKühlerschlauch 2
BKabel des Motorstoppschalters “ENGINE STOP”
CNebenkabelbaum
DMassekabel
EZündbox-Halterung
FZündbox
GKabelführung
HZündspulenkabel
IGaszug
ÈDen Warmstartzug und die Gaszüge am Rah-
men befestigen. Die Klemmen-Enden müssen
sich unter dem Warmstartzug befinden.
ÉDen Warmstartzug, die Gaszüge, das Drossel-
klappensensor-Kabel und das Zündspulen-
Kabel am Rahmen befestigen.
ÊDas Drosselklappensensor-Kabel nach der Wöl-
bung am Rahmen befestigen.
ËDas Drosselklappensensor-Kabel über den
Warmstartzug führen.
ÌDas Leerlaufschalter-Kabel hinter die Motorhal-
terung führen.
ÍDas Leerlaufschalter-Kabel über die Motor-
schutzhalterung führen.
DIAGRAMME D’ACHEMINEMENT DES CABLES
KABELFÜHRUNGSDIAGRAMME
1Câble de starter à chaud
2Collier à pince
3Fil du capteur de position de papillon des gaz
4Bosse (cadre)
5Fil du contacteur de point mort
6Support de moteur
7Support de la plaque de protection du moteur
8Fil du volant magnétique C.D.I.
9Câble d’embrayage
0Durit de mise à l’air du radiateur
ADurit de radiateur 2
BFil du bouton “ENGINE STOP”
CFaisceau de fils secondaire
DFil de terre
ESupport de boîtier CDI
FBoîtier C.D.I.
GGuide-câble
HFil de la bobine d’allumage
ICâble des gaz
ÈFixer le câble de démarrage à chaud et les câbles des
gaz au cadre. Placer les extrémités du collier à pince
sous le câble de démarrage à chaud.
ÉAttacher le câble de starter à chaud, les câbles des
gaz, le fil du capteur de position de papillon des gaz
et le fil de la bobine d’allumage au cadre.
ÊFixer le câble du capteur de position de papillon des
gaz derrière la bosse du cadre.
ËAcheminer le câble du capteur de position de papillon
des gaz au-dessus du câble de starter à chaud.
ÌAcheminer le fil du contacteur de point mort à l’inté-
rieur du support de moteur.
ÍAcheminer le fil du contacteur de point mort au-des-
sus du support de la plaque de protection.

2 - 23
SPECCABLE ROUTING DIAGRAM
ÎFasten the neutral switch lead
and radiator breather hose to
the frame.
ÏFasten the neutral switch lead,
CDI magneto lead and radiator
breather hose to the frame.
ÐFasten the neutral switch lead,
CDI magneto lead, radiator
breather hose and clutch cable
to the frame over the radiator
mounting boss.ÑPass the radiator breather hose
in front of the radiator hose 2, on
the left of the chassis, and then
between the frame and radiator
hose 4.
ÒFasten the sub wire harness and
“ENGINE STOP” button lead to
the CDI unit bracket with the
clamp ends facing downward
behind the location where the
ground lead branches out from
the sub wire harness.ÓFasten the ground lead and
cable guide together to the CDI
unit bracket.
ÔLocate the clamp ends in the
arrowed range.
ÕFasten the neutral switch lead
and CDI magneto lead to the
frame over its hump.
C-C
G-G
E
2
Õ
4 58E
É
D GGA
AB
D
5
ÌÍ Í
Í Î
F
E
D
2
2
2
Ï Ð Ò
Ñ Ó
1
G
2
3
4 2
0
8
5
9
8Ë Ê
0
0 8 5
CC
B
È 2
9
FF
Ô
Ô
B-B
A-A
I
H
3
1
C
B
A
0
0
8
5
D-D
3 F-F
6
7
2 5 0

2 - 23
SPEC
ÎDas Leerlaufschalter-Kabel und den Kühler-Ent-
lüftungsschlauch am Rahmen befestigen.
ÏDas Leerlaufschalterkabel, das Lichtmaschinen-
Kabel und den Kühler-Entlüftungsschlauch am
Rahmen befestigen.
ÐDas Leerlaufschalterkabel, das Lichtmaschinen-
Kabel, den Kühler-Entlüftungsschlauch und den
Kupplungszug über der Kühlerbefestigung am
Rahmen befestigen.
ÑDen Kühler-Entlüftungsschlauch vor dem Küh-
ler-Schlauch 2 links vom Rahmen und dann zwi-
schen Rahmen und Kühler-Schlauch 4 führen.
ÒDen Nebenkabelbaum und das Kabel des
Motorstoppschalters “ENGINE STOP” so an der
Zündbox-Halterung befestigen, dass die Klam-
mer-Enden im Bereich, wo das Massekabel vom
Nebenkabelbaum abzweigt, nach unten gerich-
tet sind.
ÓDas Massekabel und die Kabelhalterung
gemeinsam an der Zündbox-Halterung befesti-
gen.
ÔDie Klammer-Enden müssen sich innerhalb des
mit Pfeilen markierten Bereichs befinden.
ÕDas Leerlaufschalter-Kabel und das Lichtma-
schinen-Kabel am Rahmen oberhalb dessen
Wölbung befestigen.
DIAGRAMME D’ACHEMINEMENT DES CABLES
KABELFÜHRUNGSDIAGRAMME
ÎAttacher le fil du contacteur de point mort et la durit
de mise à l’air du radiateur au cadre.
ÏAttacher le fil du contacteur de point mort, le fil du
volant magnétique CDI et la durit de mise à l’air du
radiateur au cadre.
ÐAttacher le fil du contacteur de point mort, le fil du
volant magnétique CDI, la durit de mise à l’air du
radiateur et le câble d’embrayage au cadre, au-dessus
de la noix de montage du radiateur.
ÑAcheminer la durit de mise à l’air du radiateur devant
la durit de radiateur 2, à la gauche du châssis, puis
entre le cadre et la durit de radiateur 4.
ÒAttacher le faisceau de fils et le fil du bouton
“ENGINE STOP” au support de boîtier CDI, en
orientant les extrémités du collier à pince vers le bas,
derrière l’endroit où le fil de masse sort du faisceau
de fils.
ÓFixer ensemble le fil de masse et le guide-câbles au
support du boîtier CDI.
ÔLocaliser les extrémités du collier à pince dans la
plage fléchée.
ÕAttacher le fil du contacteur de point mort et le fil du
volant magnétique CDI à la bosse du cadre.

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 - 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 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 ~ 10
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 ~ 11
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

3 - 5
INSP
ADJ
EC350000
ENGINE
EC351011
COOLANT LEVEL INSPECTION
WARNING
Do not remove the radiator cap
1, drain
bolt and hoses when the engine and radia-
tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres-
sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.
CAUTION:
Hard water or salt water is harmful to the
engine parts. You may use distilled water, if
you can’t get soft water.
1. Place the machine on a level place, and
hold it in an upright position.
2. Remove:
Radiator cap
3. Check:
Coolant level a
Coolant level low → Add coolant.
1Radiator
ENGINE/COOLANT LEVEL INSPECTION