2013 YAMAHA YZ450F check oil

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.
For safety, drain the gasoline from
the fuel tank before transporting the
vehicle.

CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
LOCATION OF
IMPORTANT LABELS ..... 1-1
DESCRIPTION ................. 1-5
CONSUMER
INFORMATION................. 1-6
FEATURES....................... 1-7
INCLUDED PARTS .......... 1-9
IMPORTANT
INFORMATION................. 1-9
HANDLING THE
ELECTRONIC PARTS ... 1-10
CHECKING OF
CONNECTION ................ 1-10
SPECIAL TOOLS ........... 1-12
CONTROL
FUNCTIONS ................... 1-17
STARTING
AND BREAK-IN.............. 1-17
TORQUE-CHECK
POINTS........................... 1-19
CLEANING
AND STORAGE ............. 1-20
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS ............ 2-1
MAINTENANCE
SPECIFICATIONS ............ 2-3
TIGHTENING
TORQUES ...................... 2-11
LUBRICATION
DIAGRAMS .................... 2-17
CABLE ROUTING
DIAGRAM ....................... 2-18
CHAPTER 3
REGULAR INSPEC-
TION AND AD-
JUSTMENTS
MAINTENANCE
INTERVALS ...................... 3-1
PRE-OPERATION
INSPECTION
AND MAINTENANCE ....... 3-5
ENGINE ............................ 3-6
CHASSIS ........................ 3-14
ELECTRICAL ................. 3-24
CHAPTER 4
ENGINE
SEAT
AND SIDE COVERS ......... 4-1
EXHAUST PIPE
AND SILENCER ............... 4-3
RADIATOR ....................... 4-5
CAMSHAFTS.................... 4-8
CYLINDER HEAD........... 4-13
VALVES AND
VALVE SPRINGS ........... 4-17
CYLINDER
AND PISTON .................. 4-21
CLUTCH ......................... 4-25
OIL FILTER ELEMENT
AND WATER PUMP ....... 4-29
BALANCER .................... 4-33
OIL PUMP ....................... 4-35
KICK SHAFT
AND SHIFT SHAFT ........ 4-38
AC MAGNETO................ 4-43
ENGINE REMOVAL ....... 4-45
CRANKCASE
AND CRANKSHAFT ...... 4-50
TRANSMISSION,
SHIFT CAM
AND SHIFT FORK .......... 4-56
CHAPTER 5
CHASSIS
FRONT WHEEL
AND REAR WHEEL .........5-1
FRONT BRAKE
AND REAR BRAKE..........5-6
FRONT FORK .................5-16
HANDLEBAR..................5-24
STEERING ......................5-28
SWINGARM ....................5-32
REAR
SHOCK ABSORBER ......5-37
CHAPTER 6
FUEL SYSTEM
FUEL TANK ......................6-1
THROTTLE BODY ............6-4
CHAPTER 7
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM ...........7-1
IGNITION SYSTEM...........7-3
THROTTLE POSITION
SENSOR SYSTEM ...........7-6
FUEL INJECTION
SYSTEM............................7-9
FUEL PUMP SYSTEM ....7-35
ELECTRICAL
COMPONENTS...............7-36
CHAPTER 8
TUNING
CHASSIS ..........................8-1

1-5
DESCRIPTION
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. Front brake lever
3. Throttle grip
4. Radiator cap
5. Fuel tank cap
6. Engine stop switch
7. Kickstarter crank
8. Fuel tank
9. Radiator10. Coolant drain bolt
11. Rear brake pedal
12. Valve joint
13. Air cleaner
14. Drive chain
15. Shift pedal
16. Oil level check window
17. Starter knob/idle screw
18. Front fork

1-10
HANDLING THE ELECTRONIC PARTS
4. During the machine disassembly,
clean all parts and place them in
trays in the order of disassembly.
This will speed up assembly time
and help assure that all parts are
correctly reinstalled.
5. Keep away from fire.
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha
genuine parts for all replace-
ments. Use oil and/or grease rec-
ommended by Yamaha for
assembly and adjustment.
GASKETS, OIL SEALS AND O-
RINGS
1. All gaskets, oil seals, and O-rings
should be replaced when an en-
gine is overhauled. All gasket sur-
faces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and
bearings during reassembly. Ap-
ply grease to the oil seal lips.
LOCK WASHERS/PLATES AND
COTTER PINS
1. All lock washers/plates "1" and
cotter pins must be replaced
when they are removed. Lock
tab(s) should be bent along the
bolt or nut flat(s) after the bolt or
nut has been properly tightened.
BEARINGS AND OIL SEALS
1. Install the bearing(s) "1" and oil
seal(s) "2" with their manufactur-
er's marks or numbers facing out-
ward. (In other words, the
stamped letters must be on the
side exposed to view.) When in-
stalling oil seal(s), apply a light
coating of lightweight lithium base
grease to the seal lip(s). Oil the
bearings liberally when installing.
Do not use compressed air to spin
the bearings dry. This causes dam-
age to the bearing surfaces.
CIRCLIPS
1. All circlips should be inspected
carefully before reassembly. Al-
ways replace piston pin clips after
one use. Replace distorted cir-
clips. When installing a circlip "1",
make sure that the sharp-edged
corner "2" is positioned opposite
to the thrust "3" it receives. See
the sectional view.
HANDLING THE
ELECTRONIC PARTS
Electronic parts are very sensitive.
Handle with care and do not give
impact.
• Mankind has static electricity.
It`s voltage is very high and elec-
tronic parts are very sensitive.
• It is possible that inner small
components of electronic parts
are destroyed by static electrici-
ty.
• Do not touch and do not make
them dirty.
CHECKING OF
CONNECTION
Check the leads, couplers, and con-
nectors for stains, rust, moisture, etc.
1. Disconnect:
•Lead
• Coupler
• Connector
2. Check:
•Lead
• Coupler
• Connector
Moisture → Dry with an air blow-
er.
Rust/stains → Connect and dis-
connect several times.
3. Check:
• All connections
Loose connection → Connect
properly.
If the pin "1" on the terminal is flat-
tened, bend it up.

1-13
SPECIAL TOOLS
Cap bolt wrench
YM-01500, 90890-01500This tool is used to loosen or tighten
the base valve.
Cap bolt ring wrench
YM-01501, 90890-01501This tool is used to loosen or tighten
the damper assembly.
Fork seal driver
YM-A0948, 90890-01502 This tool is used when install the fork
oil seal.
Spoke nipple wrench
YM-01521, 90890-01521 This tool is used to tighten the
spoke.
Pocket tester
YU-03112-C, 90890-03112 Use this tool to inspect the coil resis-
tance, output voltage and amper-
age.
Timing light
YM-33277-A, 90890-03141 This tool is necessary for checking
ignition timing.
Pressure gauge
YU-03153, 90890-03153 This tool is used to measure the fuel
pressure. Tool name/Part number How to use Illustration

1-18
STARTING AND BREAK-IN
• Unlike a two-stroke engine, this
engine cannot be kick started
when the throttle is open be-
cause the kickstarter may kick
back. Also, if the throttle is open
the air/fuel mixture may be too
lean for the engine to start.
• Before starting the machine, per-
form the checks in the pre-opera-
tion check list.
AIR FILTER MAINTENANCE
According to "CLEANING THE AIR
FILTER ELEMENT" section in the
CHAPTER 3, apply the foam-air-filter
oil or its equivalent to the element.
(Excess oil in the element may ad-
versely affect engine starting.)
STARTING A COLD ENGINE
1. Inspect the coolant level.
2. Shift the transmission into neutral.
3. Pull the starter knob/ idle screw
"1" to its full length.
Use the starter knob/ idle screw be-
low an air temperature of 15°C
(59°F).
4. Push the kickstarter down lightly
with your foot until resistance is
felt.
5. With the throttle fully closed, fold
out the kickstarter lever, move it
down lightly with your foot until the
gears engage, and then push it
down smoothly but forcefully.
Do not open the throttle while kick-
ing the kickstarter crank. Other-
wise, the kickstarter crank may
kick back.
If the engine fails to start, give the
kickstarter 10 to 20 slow kicks at full
throttle in order to clear the engine of
the rich air-fuel mixture retained in it.
6. When the engine starts running,
warm it up one or two minutes at
a steady speed (of 3,000 to 5,000
r/min), and then return the starter
knob/ idle screw to its original po-
sition.
7. Push the engine stop switch "1".
Do not warm up the engine for ex-
tended periods of time.
STARTING A WARM ENGINE
To start a warm engine, make sure
that the starter (choke) knob/idling
screw is pushed in and the throttle is
closed, and then start the engine by
pushing the kickstarter crank.
If the engine fails to start, give the
kickstarter 10 to 20 slow kicks at full
throttle in order to clear the engine of
the rich air-fuel mixture retained in it.
BREAK-IN PROCEDURES
1. Before starting the engine, fill the
fuel tank with the fuel.
2. Perform the pre-operation checks
on the machine.
3. Start and warm up the engine.
Check the idle speed, and check
the operation of the controls and
the engine stop switch. Then, re-
start the engine and check its op-
eration within no more than 5
minutes after it is restarted.
4. Operate the machine in the lower
gears at moderate throttle open-
ings for five to eight minutes.
5. Check how the engine runs when
the machine is ridden with the
throttle 1/4 to 1/2 open (low to me-
dium speed) for about one hour.6. Restart the engine and check the
operation of the machine through-
out its entire operating range. Re-
start the machine and operate it
for about 10 to 15 more minutes.
The machine will now be ready to
race.
• After the break-in or before each
race, you must check the entire
machine for loose fittings and
fasteners as per "TORQUE-
CHECK POINTS". Tighten all
such fasteners as required.
• When any of the following parts
have been replaced, they must
be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in oper-
ation is necessary.
PISTON, RING, VALVES, CAM-
SHAFTS AND GEARS:
These parts require about 30
minutes of break-in operation at
half-throttle or less. Observe the
condition of the engine carefully
during operation.

2-11
TIGHTENING TORQUES
TIGHTENING TORQUES
ENGINE
△- marked portion shall be checked for torque tightening after break-in or before each race.
ItemThread
sizeQ'ty Tightening torque Remarks
Spark plug M10S 1 13 Nm (1.3 m•kg, 9.4 ft•lb)
Camshaft cap M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder head blind plug screw M12 2 28 Nm (2.8 m•kg, 20 ft•lb)
Oil passage plug M8 1 15 Nm (1.5 m•kg, 11 ft•lb)
Cylinder head (stud bolt) M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
Cylinder head (bolt) M10 4 Refer to TIP.
*1
Cylinder head (bolt) M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder head cover M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
Cylinder M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing chain tensioner M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing chain tensioner cap bolt M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Timing chain guide stopper plate (exhaust
side)M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Exhaust pipe (nut) M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
Exhaust pipe and frame M8 1 20 Nm (2.0 m•kg, 14 ft•lb)
△Silencer M8 2 30 Nm (3.0 m•kg, 22 ft•lb)
Silencer clamp (front) M8 1 12 Nm (1.2 m•kg, 8.7 ft•lb)
Silencer clamp (rear) M8 1 16 Nm (1.6 m•kg, 11 ft•lb)
Starter knob/Idle screw M12 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Throttle body joint M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Throttle body joint clamp M5 1 3 Nm (0.3 m•kg, 2.2 ft•lb)
△Air filter case M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
Air filter joint and air filter case M4 9 1 Nm (0.1 m•kg, 0.7 ft•lb)
Air filter case cover M5 2 5 Nm (0.5 m•kg, 3.6 ft•lb)
Air filter joint clamp M4 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Throttle cable adjust bolt and locknut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Throttle cable (pull) M10 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Throttle cable (return) M10 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Throttle cable cover M5 2 4 Nm (0.4 m•kg, 2.9 ft•lb)
Air duct M6 3 7 Nm (0.7 m•kg, 5.1 ft•lb)
Radiator M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
Radiator hose clamp M6 8 2 Nm (0.2 m•kg, 1.4 ft•lb)
Radiator pipe 1 M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Radiator pipe 2 M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Impeller M8 1 14 Nm (1.4 m•kg, 10 ft•lb)
Water pump housing cover M6 4 10 Nm (1.0 m•kg, 7.2 ft•lb)
Coolant drain bolt M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil pump cover M4 1 2 Nm (0.2 m•kg, 1.4 ft•lb)
Oil pump M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil pump drive gear shaft M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)

2-12
TIGHTENING TORQUES
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, remove and retighten
the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head
bolts further to reach the specified angle 150° in the proper tightening sequence.
Oil filter element cover M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil pressure check bolt M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankshaft end accessing screw M36 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Timing mark accessing screw M14 1 6 Nm (0.6 m•kg, 4.3 ft•lb)
Clutch cover M6 7 10 Nm (1.0 m•kg, 7.2 ft•lb)
Right crankcase cover M6 9 10 Nm (1.0 m•kg, 7.2 ft•lb)
Left crankcase cover M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase M6 13 12 Nm (1.2 m•kg, 8.7 ft•lb)
Clutch cable holder M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil drain bolt M8 1 20 Nm (2.0 m•kg, 14 ft•lb)
Oil drain bolt M8 1 20 Nm (2.0 m•kg, 14 ft•lb)
Oil check bolt (crankcase) M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil strainer M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Oil nozzle M5 1 8 Nm (0.8 m•kg, 5.8 ft•lb)
Crankcase bearing stopper M6 8 10 Nm (1.0 m•kg, 7.2 ft•lb)
Crankcase bearing stopper (crankshaft) M8 4 22 Nm (2.2 m•kg, 16 ft•lb) Stake.
Drive axle oil seal stopper M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Kick shaft ratchet wheel guide M62 12 Nm (1.2 m•kg, 8.7 ft•lb)Lock washer
Kickstarter crank M8 1 33 Nm (3.3 m•kg, 24 ft•lb)
Screw (kickstarter crank) M6 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Primary drive gear M20 1 100 Nm (10.0 m•kg, 72 ft•lb)
Clutch boss M20 1 75 Nm (7.5 m•kg, 54 ft•lb)
Clutch cable locknut M8 1 7 Nm (0.7 m•kg, 5.1 ft•lb)
Clutch cable adjust bolt and locknut M6 1 4 Nm (0.4 m•kg, 2.9 ft•lb)
Clutch spring M6 6 10 Nm (1.0 m•kg, 7.2 ft•lb)
Balancer M10 1 45 Nm (4.5 m•kg, 32 ft•lb) Lock washer
Balancer shaft driven gear M14 1 50 Nm (5.0 m•kg, 36 ft•lb) Lock washer
Balancer weight M6 3 10 Nm (1.0 m•kg, 7.2 ft•lb)
Drive sprocket M20 1 75 Nm (7.5 m•kg, 54 ft•lb) Lock washer
Drive chain sprocket cover M6 27 Nm (0.7 m•kg, 5.1 ft•lb)
Shift pedal M6 1 12 Nm (1.2 m•kg, 8.7 ft•lb)
Shift guide M6 2 10 Nm (1.0 m•kg, 7.2 ft•lb)
Stopper lever M6 1 10 Nm (1.0 m•kg, 7.2 ft•lb)
Segment M8 1 30 Nm (3.0 m•kg, 22 ft•lb)Item
Thread
sizeQ'ty Tightening torque Remarks