2006 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
YM-01501, 90890-01501 Cap bolt ring wrench
This tool is used to loosen or tighten the damper
assembly.YM-01501 90890-01501
YM-A0948, 90890-01502 Fork seal driver
This tool is used when install the fork oil seal.YM-A0948 90890-01502
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
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
Part number Tool name/How to use Illustration

GEN
INFO
1 - 9
SPECIAL TOOLS
YU-A9642, 90890-04152 Crankcase separating tool
These tool is used to remove the crankshaft from
either case.YU-A9642 90890-04152
YM-34487
90890-06754Dynamic spark tester
Ignition checker
This instrument is necessary for checking the ignition
system components.YM-34487 90890-06754
90890-85505 YAMAHA Bond No. 1215
(ThreeBond
 No.1215)
This sealant (Bond) is used for crankcase mating sur-
face, etc.90890-85505 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 49/13 (3.769)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio: 1st 27/14 (1.929)
2nd 23/15 (1.533)
3rd 23/18 (1.278)
4th 24/22 (1.091)
5th 20/21 (0.952)
Chassis: USA, CDN,
ZA, AUS, NZEUR
(Except for F)F
Frame type Semi double
cradle← ←
Caster angle 27.0°27.0°27.1°
Trail 115.6 mm
(4.55 in)117.0 mm
(4.61 in)117.8 mm
(4.64 in)
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 310 mm (12.2 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 2S200/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 2S2-00/YAMAHA (For USA and
CDN)
2S2-10/YAMAHA (Except for
USA and CDN)----
----
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 - 22
SPECCABLE ROUTING DIAGRAM
1Hot starter cable
2Clamp
3TPS (throttle position sensor)
lead
4Hump (frame)
5Neutral switch lead
6Engine bracket
7Engine skid plate stay
8CDI magneto lead
9Clutch cable
0Radiator breather hose
ARadiator hose 2
B“ENGINE STOP” button leadCSub wire harness
DGround lead
ECDI unit bracket
FCDI unit
GCable guide
HIgnition coil lead
IThrottle cable
ÈFasten the hot starter cable and
throttle cables onto the frame.
Locate the clamp ends under
the hot starter cable.ÉFasten the hot starter cable,
throttle cables, TPS lead and
ignition coil lead to the frame.
ÊFasten the TPS lead to the
frame behind its hump.
ËPass the TPS lead over the hot
starter cable.
ÌPass the neutral switch lead on
the inside of the engine bracket.
ÍPass the neutral switch lead
over the engine skid plate stay.
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 - 24
SPECCABLE ROUTING DIAGRAM
1Throttle cable (pull)
2Throttle cable (return)
3Radiator hose 2
4Ignition coil
5Rear arm bracket
6Cylinder head breather hoseÈPass the throttle cables over the radiator hose 2.
ÉPass the throttle cables on the outside of the igni-
tion coil.
ÊFasten the throttle cables with the clamp so that
the cables are not bent, and pass them under the
rear arm bracket.
ËPass the cylinder head breather hose so that it
does not contact the ignition coil.
B
6
Ë
A
1
2
È
6
3
5Ê
B
É
A
4

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