2007 YAMAHA YZ450F bolt pattern

3 - 20
INSP
ADJ
VALVE CLEARANCE ADJUSTMENT
5. Adjust:
Valve clearance
Adjustment steps:
Loosen the timing chain tensioner cap
bolt.
Remove the timing chain tensioner and
camshaft caps.
NOTE:
Remove the camshaft cap bolts in a criss-
cross pattern from the outside working
inwards.
Remove the camshaft (exhaust 1 and
intake 2).
NOTE:
Attach a wire 3 to the timing chain to pre-
vent it from falling into the crankcase.
Remove the valve lifters 4 and the pads
5.
NOTE:
Place a rag in the timing chain space to
prevent pads from falling into the crank-
case.
Identity each valve lifter and pad position
very carefully so that they can be rein-
stalled in their original place.
Select the proper pad using the pad
selecting table.
Pad rangePad Availability:
25 increments
No. 120
~
No. 2401.20 mm
~
2.40 mmPads are available
in 0.05 mm incre-
ments
NOTE:
The thickness a of each pad is indicated in
hundreths of millimeters on the pad upper
surface.
1
2
3

4 - 24
ENGCAMSHAFTS
REMOVAL POINTS
Camshaft
1. Remove:
Timing plug 1
Straight plug 2
2. Align:
“I” mark
With stationary pointer.
Checking steps:
Turn the crankshaft counterclockwise with
a wrench.
Align the “I” mark a on the rotor with the
stationary pointer b on the crankcase
cover. When the “I” mark is aligned with
the stationary pointer, the piston is at the
Top Dead Center (T.D.C.).
NOTE:
In order to be sure that the piston is at Top
Dead Center, the punch mark c on the
exhaust camshaft and the punch mark d
on the intake camshaft must align with the
cylinder head surface, as shown in the
illustration.
If there is no clearance, rotate the crank-
shaft counterclockwise one turn.
3. Loosen:
Tensioner cap bolt 1
4. Remove:
Timing chain tensioner 2
5. Remove:
Bolt (camshaft cap) 1
Camshaft caps 2
NOTE:
Remove the bolts (camshaft cap) in a criss-
cross pattern, working from the outside in.
CAUTION:
The bolts (camshaft cap) must be removed
evenly to prevent damage to the cylinder
head, camshafts or camshaft caps.
1
2
1
2

4 - 26
ENGCAMSHAFTS
4. Measure:
Camshaft-to-cap clearance
Out of specification → Measure camshaft
journal diameter.
Camshaft-to-cap clearance:
0.028 ~ 0.062 mm
(0.0011 ~ 0.0024 in)
: 0.08 mm (0.003 in)
Measurement steps:
Install the camshaft onto the cylinder
head.
Position a strip of Plastigauge
® 1 onto the
camshaft.
Install the circlip, dowel pins and camshaft
caps.
T R..
Bolt (camshaft cap):
10 Nm (1.0 m  kg, 7.2 ft  lb)
NOTE:
Tighten the bolts (camshaft cap) in a criss-
cross pattern from innermost to outer
caps.
Do not turn the camshaft when measuring
clearance with the Plastigauge®.
Remove the camshaft caps and measure
the width of the Plastigauge
® 1.
5. Measure:
Camshaft journal diameter a
Out of specification → Replace the cam-
shaft.
Within specification → Replace camshaft
case and camshaft caps as a set.
Camshaft sprocket
1. Inspect:
Camshaft sprocket 1
Wear/damage → Replace the camshaft
assembly and timing chain as a set.
Camshaft journal diameter:
21.959 ~ 21.972 mm
(0.8645 ~ 0.8650 in)

4 - 55
ENGCLUTCH
8. Install:
Clutch spring
Bolt (clutch spring)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
9. Install:
Gasket (clutch cover) 1
Dowel pin 2
New
10. Install:
Clutch cover 1
Bolt (clutch cover)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4 - 60
ENG
OIL FILTER, WATER PUMP AND CRANKCASE COVER
(RIGHT)
EC4G5220
Impeller shaft
1. Install:
Impeller shaft 1
Plain washer 2
Impeller 3
NOTE:
Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
When installing the impeller shaft, apply the
engine oil on the oil seal lip, bearing and
impeller shaft. And install the shaft while
turning it.
Hold the impeller shaft on its width across
the flats a with spanners, etc. and install the
impeller.
T R..14 Nm (1.4 m · kg, 10 ft · lb)
Crankcase cover (right)
1. Install:
Dowel pin 1
O-ring 2
Collar 3
Gasket 4
NOTE:
Apply the lithium soap base grease on the O-
ring.
New
New
2. Install:
Crankcase cover (right) 1
Bolt 2
Bolt
NOTE:
Apply the engine oil on the impeller shaft
end.
When installing the crankcase cover onto the
crankcase, be sure that the impeller shaft
end 2 aligns with the balancer end slot 3.
Tighten the bolts in stage, using a crisscross
pattern.
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 - 80
ENGCDI MAGNETO
2. Install:
Woodruff key 1
Rotor 2
NOTE:
Clean the tapered portions of the crankshaft
and rotor.
When installing the woodruff key, make sure
that its flat surface a is in parallel with the
crankshaft center line b.
When installing the rotor, align the keyway c
of the rotor with the woodruff key.
3. Install:
Plain washer
Nut (rotor) 1
T R..56 Nm (5.6 m · kg, 40 ft · lb)
4. Connect:
CDI magneto lead
Refer to “CABLE ROUTING DIAGRAM”
section in the CHAPTER 2.
5. Install:
Dowel pin
O-ring
Gasket [crankcase cover (left)]
Crankcase cover (left) 1
Hose holder (cylinder head breather
hose) 2
Bolt [crankcase cover (left)]
NOTE:
Apply the lithium soap base grease on the O-
ring.
Tighten the bolts in stage, using a crisscross
pattern.
New
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

4 - 94
ENGCRANKCASE AND CRANKSHAFT
5. Install:
Dowel pin 1
O-ring 2
Crankcase (right)
To crankcase (left).
NOTE:
Apply the lithium soap base grease on the O-
ring.
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)

5 - 5
CHASFRONT WHEEL AND REAR WHEEL
EC595000
ASSEMBLY AND INSTALLATION
Front wheel
1. Install:
Bearing (left) 1
Spacer 2
Bearing (right) 3
Oil seal 4
NOTE:
Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
Use a socket that matches the outside diam-
eter of the race of the bearing.
Left side of bearing shall be installed first.
Install the oil seal with its manufacture’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of the bearing.
Contact should be made only with the outer
race.
2. Install:
Brake disc 1
Bolt (brake disc) 2
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
New
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
3. Install:
Collar 1
NOTE:
Apply the lithium soap base grease on the oil
seal lip.
Install the collars with their projections a
facing the wheel.
4. Install:
Wheel
NOTE:
Install the brake disc 1 between the brake
pads 2 correctly.