2009 YAMAHA YZ450F oil change

FOREWORD
INTRODUCTION
Congratulations on your purchase of
a Yamaha YZ series. This model is
the culmination of Yamaha's vast ex-
perience in the production of paceset-
ting racing machines. It represents
the highest grade of craftsmanship
and reliability that have made Yama-
ha a leader.
This manual explains operation, in-
spection, basic maintenance and tun-
ing of your machine. If you have any
questions about this manual or your
machine, please contact your Yama-
ha dealer.
Yamaha continually seeks advance-
ments in product design and quality.
Therefore, while this manual contains
the most current product information
available at the time of printing, there
may be minor discrepancies between
your machine and this manual. If you
have any questions concerning this
manual, please consult your Yamaha
dealer.
PLEASE READ THIS MANUAL
CAREFULLY AND COMPLETELY
BEFORE OPERATING THIS MA-
CHINE. DO NOT ATTEMPT TO OP-
ERATE THIS MACHINE UNTIL YOU
HAVE ATTAINED A SATISFACTO-
RY KNOWLEDGE OF ITS CON-
TROLS AND OPERATING
FEATURES AND UNTIL YOU HAVE
BEEN TRAINED IN SAFE AND
PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND
CAREFUL MAINTENANCE,
ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU
SAFETY ENJOY THE CAPABILI-
TIES AND THE RELIABILITY OF
THIS MACHINE.
IMPORTANT MANUAL
INFORMATION
Particularly important information is
distinguished in this manual by the
following notations.
This is the safety alert symbol. It is
used to alert you to potential per-
sonal injury hazards. Obey all safe-
ty messages that follow this
symbol to avoid possible injury or
death. A WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious in-
jury.
A NOTICE indicates special pre-
cautions that must be taken to
avoid damage to the vehicle or oth-
er property.
A TIP provides key information to
make procedures easier or clearer.
SAFETY INFORMATION
THIS MACHINE IS DESIGNED
STRICTLY FOR COMPETITION
USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine
to be operated on any public street,
road, or highway. Off-road use on
public lands may also be illegal.
Please check local regulations before
riding.
• THIS MACHINE IS TO BE OPER-
ATED BY AN EXPERIENCED RID-
ER ONLY.
Do not attempt to operate this ma-
chine at maximum power until you
are totally familiar with its character-
istics.
• THIS MACHINE IS DESIGNED TO
BE RIDDEN BY THE OPERATOR
ONLY.
Do not carry passengers on this
machine.
• ALWAYS WEAR PROTECTIVE
APPAREL.
When operating this machine, al-
ways wear an approved helmet with
goggles or a face shield. Also wear
heavy boots, gloves, and protective
clothing. Always wear proper fitting
clothing that will not be caught in
any of the moving parts or controls
of the machine.
• ALWAYS MAINTAIN YOUR MA-
CHINE IN PROPER WORKING
ORDER.
For safety and reliability, the ma-
chine must be properly maintained.
Always perform the pre-operation
checks indicated in this manual.
Correcting a mechanical problem
before you ride may prevent an ac-
cident.
• GASOLINE IS HIGHLY FLAMMA-
BLE.
Always turn off the engine while re-
fueling. Take care to not spill any
gasoline on the engine or exhaust
system. Never refuel in the vicinity
of an open flame, or while smoking.• GASOLINE CAN CAUSE INJURY.
If you should swallow some gaso-
line, inhale excess gasoline vapors,
or allow any gasoline to get into
your eyes, contact a doctor immedi-
ately. If any gasoline spills onto
your skin or clothing, immediately
wash skin areas with soap and wa-
ter, and change your clothes.
• ONLY OPERATE THE MACHINE
IN AN AREA WITH ADEQUATE
VENTILATION.
Never start the engine or let it run
for any length of time in an enclosed
area. Exhaust fumes are poison-
ous. These fumes contain carbon
monoxide, which by itself is odor-
less and colorless. Carbon monox-
ide is a dangerous gas which can
cause unconsciousness or can be
lethal.
• PARK THE MACHINE CAREFUL-
LY; TURN OFF THE ENGINE.
Always turn off the engine if you are
going to leave the machine. Do not
park the machine on a slope or soft
ground as it may fall over.
• THE ENGINE, EXHAUST PIPE,
MUFFLER, AND OIL TANK WILL
BE VERY HOT AFTER THE EN-
GINE HAS BEEN RUN.
Be careful not to touch them or to
allow any clothing item to contact
them during inspection or repair.
• PROPERLY SECURE THE MA-
CHINE BEFORE TRANSPORTING
IT.
When transporting the machine in
another vehicle, always be sure it is
properly secured and in an upright
position and that the fuel cock is in
the "OFF" position. Otherwise, fuel
may leak out of the carburetor or
fuel tank.
F.I.M. MACHINE WEIGHTS
Weights of machines without fuel
The minimum weights for motocross
machines are:
for the class 125 cc:
minimum 88 kg (194 lb)
for the class 250 cc:
minimum 98 kg (216 lb)
for the class 500 cc:
minimum 102 kg (225 lb)
In modifying your machine (e.g., for
weight reduction), take note of the
above limits of weight.

1-1
DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.
1. Clutch lever
2. Hot starter lever
3. Front brake lever
4. Throttle grip
5. Radiator cap
6. Fuel tank cap
7. Engine stop switch
8. Kickstarter crank
9. Fuel tank
10. Radiator11. Coolant drain bolt
12. Rear brake pedal
13. Valve joint
14. Fuel cock
15. Cold starter knob
16. Drive chain
17. Air cleaner
18. Shift pedal
19. Oil dipstick
20. Front fork
1

2-1
GENERAL SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model name: YZ450FY (USA, CDN, AUS, NZ)
YZ450F (EUROPE, ZA)
Model code number: 34P1 (USA,CDN)
34P2 (EUROPE)
34P4 (AUS, NZ, ZA)
Dimensions: USA, CDN, AUS, NZ, ZA EUROPE
Overall length 2,195 mm (86.42 in) 2,196 mm (86.46 in)
Overall width 825 mm (32.48 in)←
Overall height 1,305 mm (51.38 in)←
Seat height 989 mm (38.94 in) 1,000 mm (39.37 in)
Wheelbase 1,496 mm (58.90 in)←
Minimum ground clearance 373 mm (14.69 in) 374 mm (14.72 in)
Dry weight:
Without oil and fuel 99.0 kg (218 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, SAE10W-40 or SAE20W-50
Yamalube 4-R, SAE10W-50
API service SG type or higher,
JASO standard MA
(Except for USA and CDN)
SAE10W-30, SAE10W-40, SAE15W-40,
SAE20W-40 or SAE20W-50
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

3-1
MAINTENANCE INTERVALS
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
Check the valve clearances●●The engine must be cold.
Inspect●Check the valve seats and valve
stems for wear.
Replace●
VALVE SPRINGS
Inspect●Check the free length and the tilt.
Replace●
VALVE LIFTERS
Inspect●Check for scratches and wear.
Replace●
CAMSHAFTS Inspect the camshaft surface.
Inspect●Inspect the decompression system.
Replace●
CAMSHAFT SPROCKETS
Inspect●Check for wear on the teeth and for
damage.
Replace●
PISTON
Inspect●●Inspect crack.
Clean●Inspect carbon deposits and eliminate
them.
Replace●
PISTON RING
Inspect●Check ring end gap.
Replace●●
PISTON PIN
Inspect●
Replace●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean●Change gasket.
CYLINDER
Inspect and clean●Inspect score marks.
Replace●Inspect wear.
3

3-10
ENGINE
4. If the oil filter is to be replaced dur-
ing this oil change, remove the fol-
lowing parts and reinstall them.
Replacement steps:
a. Remove the oil filter element cov-
er "1" and oil filter element "2".
b. Check the O-rings "3", if cracked
or damaged, replace them with a
new one.
c. Install the oil filter element and oil
filter element cover.
5. Install:
• Gaskets
• Oil filter drain bolt
• Drain bolt (right crankcase)
• Drain bolt (left crankcase)6. Fill:
• Engine oil
7. Install:
• Oil filler cap
8. Inspect:
• Engine (for oil leaks)
• Oil level
Refer to "ENGINE OIL LEVEL IN-
SPECTION".
CHECKING THE OIL PRESSURE
1. Check:
• Oil pressure
Checking steps:
a. Slightly loosen the oil pressure
check bolt "1".
b. Start the engine and keep it idling
until oil starts to seep from the oil
pressure check bolt. If no oil
comes out after one minute, turn
the engine off so it will not seize.
c. Check oil passages and oil pump
for damage or leakage.
d. Start the engine after solving the
problem(s) and recheck the oil
pressure.
e. Tighten the oil pressure check
bolt.
ADJUSTING THE PILOT SCREW
1. Adjust:
•Pilot screw "1"
Adjustment steps:
To optimize the fuel flow at a smaller
throttle opening, each machine's pilot
screw has been individually set at the
factory. Before adjusting the pilot
screw, turn it in fully and count the
number of turns. Record this number
as the factory-set number of turns
out.
a. Turn in the pilot screw until it is
lightly seated.
b. Turn out the pilot screw by the
factory-set number of turns.
ADJUSTING THE ENGINE IDLING
SPEED
1. Start the engine and thoroughly
warm it up.
2. Adjust:
• Engine idling speed
Adjustment steps:
a. Adjust the pilot screw.
Refer to "ADJUSTING THE PI-
LOT SCREW" section.
b. Turn the throttle stop screw "1"
until the specified engine idling
speed.
Using a digital engine tachometer for
idle speed adjustment, detect the en-
gine idling speed by bringing the
sensing element "c" of the engine ta-
chometer close to the ignition coil "2".
Oil filter element cover:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Oil filter drain bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Drain bolt (right crank-
case):
20 Nm (2.0 m•kg, 14
ft•lb)
Drain bolt (left crank-
case):
20 Nm (2.0 m•kg, 14
ft•lb)
Oil quantity:
Periodic oil change:
0.95 L (0.84 Imp qt,
1.00 US qt)
With oil filter replace-
ment:
1.0 L (0.88 Imp qt, 1.06
US qt)
Total amount:
1.2 L (1.06 Imp qt, 1.27
US qt)
Oil pressure check bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Pilot screw (example):
1-1/2 turns out
Digital tachometer:
YU-39951-B/90890-
06760
To increase idle speed→Turn the
throttle stop screw "1" in "a".
To decrease idle speed→Turn the
throttle stop screw "1" out "b".

3-19
CHASSIS
Do not force the adjuster past the
minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Always adjust each front fork to
the same setting. Uneven adjust-
ment can cause poor handling and
loss of stability.
CHECKING THE REAR SHOCK
ABSORBER
1. Inspect:
• Swingarm smooth action
Abnormal noise/unsmooth action
→Grease the pivoting points or
repair the pivoting points.
Damage/oil leakage→Replace.
ADJUSTING THE REAR SHOCK
ABSORBER SPRING PRELOAD
1. Elevate the rear wheel by placing
the suitable stand under the en-
gine.
2. Remove:
• Rear frame
3. Measure:
• Spring fitting length• The I.D. mark "a" is marked at the
end of the spring.
• Spring specification varies accord-
ing to the difference in the produc-
tion lot.
4. Adjust:
• Spring preload
Adjustment steps:
a. Loosen the locknut "1".
b. Loosen the adjuster "2" until there
is some clearance between the
spring and adjuster.
c. Measure the spring free length
"a".
d. Turn the adjuster "2".
ŒBe sure to remove all dirt and mud
from around the locknut and adjust-
er before adjustment.
• The length of the spring (installed)
changes 1.5 mm (0.06 in) per turn
of the adjuster.
Never attempt to turn the adjuster
beyond the maximum or minimum
setting.
e. Tighten the locknut.
5. Install:
• Rear frame (upper)
• Rear frame (lower)
ADJUSTING THE REAR SHOCK
ABSORBER REBOUND DAMPING
FORCE
1. Adjust:
• Rebound damping force
By turning the adjuster "1". Standard position:
12 clicks out
* 10 clicks out
* Except for USA and CDN
Standard fitting length:
I.D. MARK/
Q'TYLength
Pink/1
Pink/2
Pink/3266 mm
(10.47 in)
*263 mm
(10.35 in)
272 mm
(10.71 in)
*269 mm
(10.59 in)
263.5 mm
(10.37 in)
*260.5 mm
(10.26 in)
* Except for USA and CDN
Stiffer →Increase the spring pre-
load. (Turn the adjuster "2" in.)
Softer→Decrease the spring pre-
load. (Turn the adjuster "2"
out.)
Extent of adjustment:
Maximum Minimum
Position in
which the
spring is turned
in 13 mm (0.51
in) from its free
length.Position in
which the
spring is turned
in 1.5 mm (0.06
in) from its free
length.
Locknut:
30 Nm (3.0 m•kg, 22
ft•lb)
Rear frame (upper):
38 Nm (3.8 m•kg, 27
ft•lb)
Rear frame (lower):
32 Nm (3.2 m•kg, 23
ft•lb)
Stiffer "a" →Increase the re-
bound damping force. (Turn
the adjuster "1" in.)
Softer "b" →Decrease the re-
bound damping force. (Turn
the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum
Fully turned in
position20 clicks out
(from maximum
position)

4-35
OIL FILTER ELEMENT AND WATER PUMP
REMOVING THE IMPELLER
SHAFT
1. Remove:
•Impeller "1"
• Washer "2"
• Impeller shaft "3"
Hold the impeller shaft on its width
across the flats "a" with spanners,
etc. and remove the impeller.
REMOVING THE OIL SEAL
It is not necessary to disassemble the
water pump, unless there is an abnor-
mality such as excessive change in
coolant level, discoloration of coolant,
or milky transmission oil.
1. Remove:
• Bearing "1"
•Oil seal "2"
CHECKING THE IMPELLER SHAFT
1. Inspect:
• Impeller shaft "1"
Bend/wear/damage→Replace.
Fur deposits→Clean.CHECKING THE BEARING
1. Inspect:
• Bearing
Rotate inner race with a finger.
Rough spot/seizure→Replace.
CHECKING THE OIL SEAL
1. Inspect:
• Oil seal "1"
Wear/damage→Replace.
INSTALLING THE OIL SEAL
1. Install:
• Oil seal "1"
• Apply the lithium soap base grease
on the oil seal lip.
• Install the oil seal with its manufac-
ture's marks or numbers facing the
right crankcase cover "2".
2. Install:
• Bearing "1"
Install the bearing by pressing its out-
er race parallel.
INSTALLING THE IMPELLER
SHAFT
1. Install:
• Impeller shaft "1"
• Washer "2"
• Impeller "3"
• Take care so that the oil seal lip is
not damaged or the spring does not
slip off its position.
• 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.
INSTALLING THE RIGHT
CRANKCASE COVER
1. Install:
• Dowel pin "1"
• O-ring "2"
•Collar "3"
• Gasket "4"
Apply the lithium soap base grease
on the O-ring.
Impeller:
14 Nm (1.4 m•kg, 10
ft•lb)

5-25
HANDLEBAR
REMOVING THE BRAKE MASTER
CYLINDER
1. Remove:
• Brake master cylinder bracket "1"
• Brake master cylinder "2"
• Do not let the brake master cylin-
der hang on the brake hose.
• Keep the brake master cylinder
cap side horizontal to prevent air
from coming in.
REMOVING THE GRIP
1. Remove:
•Grip "1"
Blow in air between the handlebar or
tube guide and the grip. Then remove
the grip which has become loose.
CHECKING THE HANDLEBAR
1. Inspect:
• Handlebar "1"
Bends/cracks/damage→Re-
place.
Do not attempt to straighten a bent
handlebar as this may dangerous-
ly weaken the handlebar.
INSTALLING THE HANDLEBAR
1. Install:
• Handlebar lower holder "1"
• Washer "2"
• Nut (handlebar lower holder) "3"
• Be sure the side of the handlebar
lower holder having the greater dis-
tance "a" from the mounting bolt
center faces forward. And install it
in the hole "b" in the rear of the up-
per bracket.
• Apply the lithium soap base grease
on the thread of the handlebar low-
er holder.
• Change in the direction back to
front and installing position of the
handlebar lower holder allows the
front-to-rear offset amount of the
handlebar position to be changed.
• Do not tighten the nut yet.
A. Forward
2. Install:
• Handlebar "1"
• Handlebar upper holder "2"
• Bolt (handlebar upper holder) "3"
• The handlebar upper holder should
be installed with the punched mark
"a" forward.
• Install the handlebar so that the
marks "b" are in place on both
sides.
• Install the handlebar so that the pro-
jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• First tighten the bolts on the front
side of the handlebar upper holder,
and then tighten the bolts on the
rear side.
3. Tighten:
• Nut (handlebar lower holder) "1"
4. Install:
• Left grip "1"
Apply the adhesive to the handle-
bar "2".
• Before applying the adhesive, wipe
off grease or oil on the handlebar
surface "a" with a lacquer thinner.
• Install the left grip to the handlebar
so that the line "b" between the two
arrow marks faces straight upward.
Bolt (handlebar upper
holder):
28 Nm (2.8 m•kg, 20
ft•lb)
Nut (handlebar lower
holder):
34 Nm (3.4 m•kg, 24
ft•lb)