2009 YAMAHA YZ450F bolt pattern

4-16
CAMSHAFTS
REMOVING THE CAMSHAFT
1. Remove:
• Timing mark accessing screw "1"
• Crankshaft end accessing screw
"2"
2. Align:
• T.D.C. mark
With align mark.
Checking steps:
a. Turn the crankshaft counterclock-
wise with a wrench.
b. Align the T.D.C. mark "a" on the
rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
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 cam-
shaft must align with the cylinder
head surface, as shown in the illustra-
tion.
3. Remove:
• Timing chain tensioner cap bolt
"1"
• Timing chain tensioner "2"
•Gasket4. Remove:
• Bolt (camshaft cap) "1"
• Camshaft cap "2"
•Clip
Remove the bolts (camshaft cap) in a
crisscross pattern, working from the
outside in.
The bolts (camshaft cap) must be
removed evenly to prevent dam-
age to the cylinder head, cam-
shafts or camshaft caps.
5. Remove:
• Exhaust camshaft "1"
• Intake camshaft "2"
Attach a wire "3" to the timing chain to
prevent it from falling into the crank-
case.
CHECKING THE CAMSHAFT
1. Inspect:
• Cam lobe
Pitting/scratches/blue discolora-
tion→Replace.
2. Measure:
• Cam lobe length "a" and "b"
Out of specification→Replace.3. Measure:
• Runout (camshaft)
Out of specification→Replace.
4. Measure:
• Camshaft-to-cap clearance
Out of specification→Measure
camshaft outside diameter.
Cam lobes length:
Intake "a":
31.200–31.300 mm
(1.2283–1.2323 in)
:
31.100 mm (1.2244 in)
Intake "b":
22.550–22.650 mm
(0.8878–0.8917 in)
:
22.450 mm (0.8839 in)
Exhaust "a":
30.900–31.000 mm
(1.2165–1.2205 in)
:
30.800 mm (1.2126 in)
Exhaust "b":
22.468–22.568 mm
(0.8846–0.8885 in)
:
22.368 mm (0.8806 in)
Runout (camshaft):
Less than 0.03 mm
(0.0012 in)

4-17
CAMSHAFTS
Measurement steps:
a. Install the camshaft onto the cylin-
der head.
b. Position a strip of Plastigauge
®
"1" onto the camshaft.
c. Install the clip, dowel pins and
camshaft caps.
• Tighten the bolts (camshaft cap) in
a crisscross pattern from innermost
to outer caps.
• Do not turn the camshaft when
measuring clearance with the Plas-
tigauge
®.
d. Remove the camshaft caps and
measure the width of the Plasti-
gauge
® "1".
5. Measure:
• Camshaft outside diameter "a"
Out of specification→Replace the
camshaft.
Within specification→Replace
camshaft case and camshaft
caps as a set.CHECKING THE CAMSHAFT
SPROCKET
1. Inspect:
• Camshaft sprocket "1"
Wear/damage→Replace the
camshaft assembly and timing
chain as a set.
CHECKING THE
DECOMPRESSION SYSTEM
1. Check:
• Decompression system
Checking steps:
a. Check that the decompression
mechanism cam "1" moves
smoothly.
b. Check that the decompression
mechanism cam lever pin "2"
projects from the camshaft.
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• While pressing the tensioner rod
lightly with fingers, use a thin
screwdriver "1" and wind the ten-
sioner rod up fully clockwise.
• When releasing the screwdriver
by pressing lightly with fingers,
make sure that the tensioner rod
will come out smoothly.
• If not, replace the tensioner as-
sembly.INSTALLING THE CAMSHAFT
1. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"
Installation steps:
a. Turn the crankshaft counterclock-
wise with a wrench.
• Apply the molybdenum disulfide oil
on the camshafts.
• Apply the engine oil on the decom-
pression system.
b. Align the T.D.C. mark "a" on the
rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
c. Fit the timing chain "3" onto both
camshaft sprockets and install the
camshafts on the cylinder head.
The camshafts should be installed
onto the cylinder head so that the
punch mark "c" on the exhaust cam-
shaft and the punch mark "d" on the
intake camshaft must align with the
cylinder head surface, as shown in
the illustration.
Camshaft-to-cap clear-
ance:
0.028–0.062 mm
(0.0011–0.0024 in)
:0.08 mm (0.003
in)
Bolt (camshaft cap):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Camshaft outside diame-
ter:
21.959–21.972 mm
(0.8645–0.8650 in)

4-20
CYLINDER HEAD
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Carbon deposits (from the com-
bustion chambers)
Use a rounded scraper.
Do not use a sharp instrument to
avoid damaging or scratching:
• Spark plug threads
•Valve seats
2. Inspect:
• Cylinder head
Scratches/damage→Replace.
3. Measure:
• Cylinder head warpage
Out of specification→Resurface.
Warpage measurement and resur-
facing steps:
a. Place a straightedge and a feeler
gauge across the cylinder head.
b. Use a feeler gauge to measure
the warpage.
c. If the warpage is out of specifica-
tion, resurface the cylinder head.
d. Place a 400–600 grit wet sandpa-
per on the surface plate, and re-
surface the head using a figure-
eight sanding pattern.
To ensure an even surface rotate the
cylinder head several times.
INSTALLING THE CYLINDER
HEAD
1. Install:
• Timing chain guide (exhaust side)
"1"
• Dowel pin "2"
• Cylinder head gasket "3" • Cylinder head "4"
While pulling up the timing chain, in-
stall the timing chain guide (exhaust
side) and cylinder head.
2. Install:
•Washer "1"
•Bolts "2"
Installation steps:
Tighten the cylinder head using
the rotation angle procedure to ob-
tain uniform tightening torque.
a. Wash the threads and contact
surfaces of the bolts, the contact
surfaces of the plain washers, the
contact surface of the cylinder
head, and the threads of the
crankcase.
b. Apply the molybdenum disulfide
grease on the threads and con-
tact surfaces of the bolts and on
both contact surfaces of the plain
washers.
c. Install the plain washers and
bolts.
d. Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.e. Remove the bolts.
f. Again apply the molybdenum dis-
ulfide grease on the threads and
contact surfaces of the bolts and
on both contact surfaces of the
plain washers.
g. Retighten the bolts.
Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.
h. Put a mark on the corner "1" of the
bolt (cylinder head) and the cylin-
der head "2" as shown.
Tighten the bolts 90° in each of the
two steps to reach the specified angle
of 180° in the proper tightening se-
quence as shown.
Cylinder head warpage:
Less than 0.05 mm
(0.002 in)
Bolts (cylinder head):
1st:
30 Nm (3.0 m•kg, 22
ft•lb)
Bolts (cylinder head):
2nd:
20 Nm (2.0 m•kg, 14
ft•lb)
Bolts (cylinder head):
Final:
Specified angle 180°

4-32
CLUTCH
2. Install:
• Lock washer "1"
• Nut (clutch boss) "2"
Make sure to tighten to specifica-
tion; otherwise, it may damage the
other part that is fastened togeth-
er.
• Install the lock washer with its con-
caves fitted over the convexes of
the clutch boss.
• Use the clutch holding tool "3" to
hold the clutch boss.
A. For USA and CDN
B. Except for USA and CDN
3. Bend the lock washer "1" tab.
4. Install:
• Friction plate "1"
• Clutch plate "2"
• Install the clutch plates and friction
plates alternately on the clutch
boss, starting with a friction plate
and ending with a friction plate.
• Apply the engine oil on the friction
plates and clutch plates.
5. Install:
• Bearing "1"
•Washer "2"
•Circlip "3"
To push rod 1 "4".
Apply the engine oil on the bearing
and washer.
6. Install:
• Push rod 2 "1"
•Ball "2"
• Push rod 1 "3"
Apply the engine oil on the push rod
1, 2 and ball.
7. Install:
• Pressure plate "1"
8. Install:
• Clutch spring
• Bolt (clutch spring)
Tighten the bolts in stage, using a
crisscross pattern.
9. Install:
• Gasket (clutch cover) "1"
• Dowel pin "2"
10. Install:
• Clutch cover "1"
• Bolt (clutch cover)
Tighten the bolts in stage, using a
crisscross pattern.
Nut (clutch boss):
75 Nm (7.5 m•kg, 54
ft•lb)
Clutch holding tool:
YM-91042/90890-04086
Bolt (clutch spring):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (clutch cover):
10 Nm (1.0 m•kg, 7.2
ft•lb)

4-36
OIL FILTER ELEMENT AND WATER PUMP
2. Install:
• Right crankcase cover "1"
•Bolt "2"
•Bolt
• Apply the engine oil on the impeller
shaft end.
• When installing the crankcase cov-
er 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.
INSTALLING THE KICKSTARTER
CRANK
1. Install:
• Kickstarter crank "1"
• Washer
• Bolt (kickstarter crank)
Install so that there is a clearance "a"
of 8 mm (0.31 in) or more between
the kickstarter and frame and that the
kickstarter does not contact the
crankcase cover when it is pulled.
2. Install:
• Oil tank breather hose "1"
•Clamp "2"
INSTALLING THE WATER PUMP
HOUSING
1. Install:
• Dowel pin "1"
• O-ring "2"
Apply the lithium soap base grease
on the O-ring.
2. Install:
• Water pump housing "1"
• Bolt (water pump housing) "2"
• Washer "3"
• Coolant drain bolt "4"3. Install:
• O-ring
• Coolant pipe "1"
• Bolt (coolant pipe) "2"
Apply the lithium soap base grease
on the O-ring.
INSTALLING THE OIL FILTER
ELEMENT
1. Install:
• Oil filter element "1"
• O-ring "2"
• Oil filter element cover "3"
• Bolt (oil filter element cover)
Apply the lithium soap base grease
on the O-ring.
Bolt:
12 Nm (1.2 m•kg, 8.7
ft•lb)
Bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (kickstarter crank):
33 Nm (3.3 m•kg, 24
ft•lb)Clamp:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Bolt (water pump hous-
ing):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Coolant drain bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (coolant pipe):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (oil filter element
cover):
10 Nm (1.0 m•kg, 7.2
ft•lb)

4-48
CDI MAGNETO
REMOVING THE ROTOR
1. Remove:
• Nut (rotor) "1"
• Washer
2. Remove:
• Rotor "1"
Use the rotor puller 2.
CHECKING THE CDI MAGNETO
1. Inspect:
• Rotor inner surface "a"
• Stator outer surface "b"
Damage→Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace CDI magne-
to and/or stator.
CHECKING THE WOODRUFF KEY
1. Inspect:
• Woodruff key "1"
Damage→Replace.
INSTALLING THE CDI MAGNETO
1. Install:
• Stator "1"
• Screw (stator) "2"
• Apply the sealant on the grommet
of the CDI magneto lead.
• Tighten the screws using the T30
bit.
2. Install:
• Woodruff key "1"
•Rotor "2"
• Degrease the contact surfaces of
the tapered portions of the crank-
shaft 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:
•Washer
• Nut (rotor) "1"
4. Connect:
• CDI magneto lead
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.5. Install:
• Dowel pin
• O-ring
• Gasket (left crankcase cover)
• Left crankcase cover "1"
• Hose guide (cylinder head breath-
er hose) "2"
• Bolt (left crankcase cover)
• Apply the lithium soap base grease
on the O-ring.
• Tighten the bolts in stage, using a
crisscross pattern.
Rotor puller:
YM-04151/90890-04151
Screw (stator):
10 Nm (1.0 m•kg,
7.2ft•lb)
YAMAHA Bond No. 1215
(ThreeBond® No. 1215):
90890-85505
Nut (rotor):
56 Nm (5.6 m•kg, 40
ft•lb)
Bolt (left crankcase cov-
er):
10 Nm (1.0 m•kg, 7.2
ft•lb)

5-4
FRONT WHEEL AND REAR WHEEL
2. Install:
•Brake disc "1"
• Bolt (brake disc) "2"
Tighten the bolts in stage, using a
crisscross pattern.
3. Install:
•Collar "1"
• Apply the lithium soap base grease
on the oil seal lip.
• Install the collars with their projec-
tions "a" facing the wheel.
4. Install:
• Wheel
Install the brake disc "1" between the
brake pads "2" correctly.
5. Install:
• Wheel axle "1"
Apply the lithium soap base grease
on the wheel axle.
6. Install:
• Nut (wheel axle) "1"
7. Tighten:
• Bolt (axle holder) "1"
Before tightening the bolt, fit the
wheel axle to the axle holder by strok-
ing the front fork several times with
the front brake applied.
INSTALLING THE REAR WHEEL
1. Install:
• Bearing (right) "1"
•Circlip "2"
•Spacer "3"
• Bearing (left) "4"
• Oil seal "5"
• Apply the lithium soap base grease
on the bearing and oil seal lip when
installing.
• Install the bearing with seal facing
outward.
• Use a socket that matches the out-
side diameter of the race of the
bearing.
• Right side of bearing shall be in-
stalled first.
• Install the oil seal with its manufac-
ture's marks or numbers facing out-
ward.
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"
Tighten the bolts in stage, using a
crisscross pattern.
3. Install:
• Rear wheel sprocket "1"
• Bolt (rear wheel sprocket) "2"
• Washer (rear wheel sprocket) "3"
• Nut (rear wheel sprocket) "4"
Tighten the nuts in stage, using a
crisscross pattern.
Bolt (brake disc):
12 Nm (1.2 m•kg, 8.7
ft•lb)
Nut (wheel axle):
105 Nm (10.5 m•kg, 75
ft•lb)
Bolt (axle holder):
21 Nm (2.1 m•kg, 15
ft•lb)
Bolt (brake disc):
14 Nm (1.4 m•kg, 10
ft•lb)
Nut (rear wheel sprock-
et):
42 Nm (4.2 m•kg, 30
ft•lb)