2008 YAMAHA YZ450F oil filter

CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
DESCRIPTION ................. 1-1
MACHINE
IDENTIFICATION ............ 1-2
INCLUDED PARTS .......... 1-2
IMPORTANT
INFORMATION................. 1-2
CHECKING OF CONNEC-
TION ................................. 1-3
SPECIAL TOOLS ............. 1-4
CONTROL FUNCTIONS .. 1-8
STARTING AND
BREAK-IN ........................ 1-8
TORQUE-CHECK
POINTS........................... 1-11
CLEANING AND
STORAGE ...................... 1-12
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICA-
TIONS ............................... 2-1
MAINTENANCE SPECIFICA-
TIONS ............................... 2-3
TIGHTENING
TORQUES ...................... 2-10
LUBRICATION
DIAGRAMS .................... 2-16
CABLE ROUTING
DIAGRAM ....................... 2-18
CHAPTER 3
REGULAR INSPEC-
TION AND AD-
JUSTMENTS
MAINTENANCE
INTERVALS...................... 3-1PRE-OPERATION
INSPECTION AND MAINTE-
NANCE ............................. 3-4
ENGINE ............................ 3-5
CHASSIS ........................ 3-13
ELECTRICAL ................. 3-22
CHAPTER 4
ENGINE
SEAT, FUEL TANK AND
SIDE COVERS.................. 4-1
EXHAUST PIPE AND
SILENCER ........................ 4-3
RADIATOR ....................... 4-5
CARBURETOR................. 4-7
CAMSHAFTS.................. 4-14
CYLINDER HEAD........... 4-19
VALVES AND VALVE
SPRINGS ........................ 4-22
CYLINDER AND
PISTON ........................... 4-26
CLUTCH ......................... 4-29
OIL FILTER ELEMENT
AND WATER PUMP ....... 4-33
BALANCER .................... 4-37
OIL PUMP ....................... 4-39
KICK SHAFT AND SHIFT
SHAFT ............................ 4-42
CDI MAGNETO............... 4-47
ENGINE REMOVAL ....... 4-49
CRANKCASE AND CRANK-
SHAFT ............................ 4-53
TRANSMISSION, SHIFT
CAM AND SHIFT FORK. 4-59
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR
WHEEL ............................. 5-1
FRONT BRAKE AND REAR
BRAKE ............................. 5-6
FRONT FORK................. 5-16
HANDLEBAR ................. 5-24STEERING ......................5-28
SWINGARM ....................5-32
REAR SHOCK
ABSORBER ....................5-37
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPO-
NENTS AND WIRING DIA-
GRAM ...............................6-1
IGNITION SYSTEM...........6-2
THROTTLE POSITION SEN-
SOR SYSTEM ...................6-5
CHAPTER 7
TUNING
ENGINE.............................7-1
CHASSIS ..........................7-6

2-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name: YZ450FX (USA, CDN, AUS, NZ)
YZ450F (EUROPE, ZA)
Model code number: 2S2B (USA,CDN)
2S2C (EUROPE)
2S2E (AUS, NZ, ZA)
Dimensions: USA, CDN, AUS, NZ, ZA EUROPE
Overall length 2,194 mm (86.38 in) 2,195 mm (86.42 in)
Overall width 825 mm (32.48 in)
←
Overall height 1,306 mm (51.42 in)←
Seat height 990 mm (38.98 in) 1,001 mm (39.41 in)
Wheelbase 1,495 mm (58.86 in)
←
Minimum ground clearance 374 mm (14.72 in) 375 mm (14.76 in)
Dry weight:
Without oil and fuel 99.5 kg (219 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 449 cm
3 (15.8 Imp oz, 15.2 US oz)
Bore × stroke 95.0 × 63.4 mm (3.74 × 2.50 in)
Compression ratio 12.3 : 1
Starting system Kickstarter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For USA and CDN)
Yamalube 4, SAE10W30 or SAE20W40
Yamalube 4-R, SAE10W50
API service SG type or higher,
JASO standard MA
(Except for USA and CDN)
SAE10W30, SAE10W40, SAE15W40,
SAE20W40 or SAE20W50
API service SG type or higher,
JASO standard MA
Oil capacity:
Engine oil
Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt)
With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt)
Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt)
Air filter: Wet type element
2

2-7
MAINTENANCE SPECIFICATIONS
Air filter oil grade: Foam-air-filter oil or equivalent oil ----
Clutch:
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110
in)
Quantity 8 ----
Clutch plate thickness 1.5–1.7 mm (0.059–0.067 in) ----
Quantity 7 ----
Warp limit ---- 0.1 mm (0.004
in)
Clutch spring free length 50.0 mm (1.97 in) 49.0 mm (1.93
in)
Quantity 6 ----
Clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ----
Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm (0.002
in)
Kickstarter:
Type Kick and ratchet type ----
Carburetor:
Type/manufacturer FCR-MX39/KEIHIN ----
I. D. mark 2S2B B0 ----
Main jet (M.J) #160 ----
Main air jet (M.A.J) ø2.0 ----
Jet needle - clip position (J.N) NFLR-3 ----
Cutaway (C.A) 1.5 ----
Pilot jet (P.J) #45 ----
Pilot air jet (P.A.J) #100 ----
Pilot outlet (P.O) ø0.9 ----
Pilot screw (example) (P.S) 1-1/2 ----
Bypass (B.P) ø1.0 ----
Valve seat size (V.S) ø3.8 ----
Starter jet (G.S) #72 ----
Leak jet (Acc.P) #55 ----
Float height (F.H) 8 mm (0.31 in) ----
Engine idle speed 1,900–2,100 r/min ----
Intake vacuum 28.0–33.3 kPa (210–250 mmHg, 8.27–
9.84 inHg)----
Hot starter lever free play 3–6 mm (0.12–0.24 in) ----
Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008
in) Item Standard Limit

2-10
TIGHTENING TORQUES
ELECTRICAL
TIGHTENING TORQUES
ENGINE
△- marked portion shall be checked for torque tightening after break-in or before each race.
Item Standard Limit
Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufacturer 2S200/YAMAHA ----
Charging coil 1 resistance (color) 720–1,080
Ωat 20 °C (68 °F) (Green–
Brown)----
Charging coil 2 resistance (color) 44–66
Ωat 20 °C (68 °F) (Black–Pink) ----
Pickup coil resistance (color) 248–372
Ωat 20 °C (68 °F) (White–Red) ----
CDI unit-model/manufacturer 2S2-B0/YAMAHA (Except for EUROPE) ----
2S2-C0/YAMAHA (For EUROPE) ----
Ignition coil:
Model/manufacturer 5TA-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08–0.10
Ωat 20 °C (68 °F) ----
Secondary coil resistance 4.6–6.8 k
Ωat 20 °C (68 °F) ----
Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M8 × 1.25 1 15 1.5 11
Cylinder head (bolt) M10 × 1.25 4 Refer to NOTE.
*1
Cylinder head (bolt) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Exhaust pipe (nut) M8 × 1.25 1 20 2.0 14
Exhaust pipe (bolt) M8 × 1.25 1 20 2.0 14
△Silencer M8 × 1.25 2 30 3.0 22
Silencer clamp M8 × 1.25 1 14 1.4 10
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
Carburetor joint M6 × 1.0 3 10 1.0 7.2
Carburetor joint clamp M4 × 0.7 1 3 0.3 2.2
△Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Throttle cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9

2-11
TIGHTENING TORQUES
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Hot starter cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Air filter element M6 × 1.0 1 2 0.2 1.4
Radiator stay M6 × 1.0 6 7 0.7 5.1
Radiator M6 × 1.0 4 10 1.0 7.2
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Radiator pipe 1, 2 M6 × 1.0 2 10 1.0 7.2
Impeller M8 × 1.25 1 14 1.4 10
Water pump housing cover M6 × 1.0 3 10 1.0 7.2
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 2 10 1.0 7.2
Oil pump drive gear shaft M6 × 1.0 1 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil pressure check bolt M6 × 1.0 1 10 1.0 7.2
△Oil hose clamp — 2 2 0.2 1.4
Crankshaft end accessing screw M27 × 1.5 1 10 1.0 7.2
Timing mark accessing screw M14 × 1.5 1 6 0.6 4.3
Clutch cover M6 × 1.0 7 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Right crankcase cover M6 × 1.0 2 12 1.2 8.7
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Crankcase M6 × 1.0 12 12 1.2 8.7
Clutch cable holder M6 × 1.0 2 10 1.0 7.2
Oil drain bolt (right crankcase) M10 × 1.25 1 20 2.0 14
Oil drain bolt (left crankcase) M8 × 1.25 1 20 2.0 14
Oil check bolt (crankcase) M6 × 1.0 1 10 1.0 7.2
Oil strainer M6 × 1.0 1 10 1.0 7.2
Crankcase bearing stopper M6 × 1.0 8 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 14 1.4 10
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Screw (kickstarter crank) M6 × 1.0 1 7 0.7 5.1
Primary drive gear M20 × 1.0 1 110 11.0 80
Clutch boss M20 × 1.0 1 75 7.5 54
Clutch cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Clutch spring M6 × 1.0 6 10 1.0 7.2
Balancer M10 × 1.0 1 45 4.5 32
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Balancer weight M6 × 1.0 3 10 1.0 7.2Part to be tightened Thread size Q'tyTightening torque
Nm m•kg ft•lb

2-16
LUBRICATION DIAGRAMS
LUBRICATION DIAGRAMS
1. Oil filter element
2. Oil pump
3. Drive axle
4. Main axle
5. Crankshaft
6. Connecting rod
A. From cylinder
B. To oil tank

3-2
MAINTENANCE INTERVALS
Replace●
TRANSMISSION
Inspect
●
Replace bearing●
SHIFT FORK, SHIFT CAM,
GUIDE BAR
Inspect
●Inspect wear.
ROTOR NUT
Retighten
●●
EXHAUST PIPE, SILENCER,
PROTECTOR
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.
Lubricate, slack, alignment
●●Chain slack: 48–58 mm (1.9–2.3 in)
Replace
●
COOLING SYSTEM
Check coolant level and leakage
●●
Check radiator cap operation●
Replace coolant●Every two years
Inspect hoses
●
OUTSIDE NUTS AND BOLTS
Retighten
●●Refer to "STARTING AND BREAK-
IN" section in the CHAPTER 1.
AIR FILTER
Clean and lubricate
●●Use foam air-filter oil or equivalent oil.
Replace
●
OIL FILTER
Replace
●●
FRAME
Clean and inspect
●●
FUEL TANK, COCK
Clean and inspect
●●
BRAKES
Adjust lever position and pedal
height
●●
ItemAfter
break-
inEvery
race
Every
third
(or 500
km)Every
fifth (or
1,000
km)
As re-
quiredRemarks

3-7
ENGINE
LUBRICATING THE THROTTLE
1. Remove:
• Cover (throttle cable cap) "1"
• Cover (grip cap) "2"
• Throttle grip cap "3"
2. Apply:
• Lithium soap base grease
On the throttle cable end "a".
3. Install:
• Throttle grip cap
• Screw (throttle grip cap)
• Cover (grip cap)
• Cover (throttle cable cap)
ADJUSTING THE HOT STARTER
LEVER FREE PLAY
1. Check:
• Hot starter lever free play "a"
Out of specification
→Adjust.
2. Adjust:
• Hot starter lever free play
Hot starter lever free play adjust-
ment steps:
a. Loosen the locknut "1".
b. Turn the adjuster "2" until free
play "a" is within the specified lim-
its.
c. Tighten the locknut.
After adjustment, check proper oper-
ation of hot starter.
CLEANING THE AIR FILTER
ELEMENT
Proper air filter maintenance is the
biggest key to preventing premature
engine wear and damage.
Never run the engine without the
air filter element in place; this
would allow dirt and dust to enter
the engine and cause rapid wear
and possible engine damage.
1. Remove:
•Seat
• Fitting bolt "1"
• Washer "2"
• Air filter element "3"
• Air filter guide "4"
2. Clean:
• Air filter element
Clean them with solvent.
After cleaning, remove the remaining
solvent by squeezing the element.
• Do not twist the element when
squeezing the element.
• Leaving too much of solvent in
the element may result in poor
starting.
3. Inspect:
• Air filter element
Damage
→Replace.
4. Apply:
• Foam-air-filter oil or equivalent oil
to the element
Squeeze out the excess oil. Element
should be wet but not dripping.
5. Install:
• Air filter guide "1"
Align the projection "a" on filter guide
with the hole "b" in air filter element.
6. Apply:
• Lithium soap base grease
On the matching surface "a" on air
filter element.
7. Install:
• Air filter element "1"
• Washer
• Fitting bolt
Align the projection "a" on filter guide
with the hole "b" in air filter case.
Screw (throttle grip cap):
4 Nm (0.4 m•kg, 2.9
ft•lb)
Hot starter lever free play
"a":
3–6 mm (0.12–0.24 in)
Locknut:
4 Nm (0.4 m•kg, 2.9
ft•lb)
Fitting bolt:
2 Nm (0.2 m•kg, 1.4
ft•lb)