2013 YAMAHA YZ450F clutch

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

1-14
SPECIAL TOOLS
FI diagnostic tool
YU-03182, 90890-03182This tool is used to check the fault
codes and diagnose any problems.
Fuel pressure adapter
YM-03186, 90890-03186This tool is used to attach the pres-
sure gauge.
Test harness S-pressure sensor
(3P)
YU-03207, 90890-03207This tool is connected between the
intake air pressure sensor and the
wire harness and is used to mea-
sure the voltage.
Test harness-speed sensor (3P)
YU-03208, 90890-03208This tool is connected between the
throttle position sensor and the wire
harness and is used to measure the
voltage.
FI diagnostic tool sub-lead
YU-03212, 90890-03212This tool is used to connect the FI di-
agnostic tool to a battery.
Valve guide remover & installer set
90890-04016This tool is needed to remove and
install the valve guide.
Valve spring compressor
YM-04019, 90890-04019This tool is needed to remove and
install the valve assemblies.
Clutch holding tool
YM-91042, 90890-04086This tool is used to hold the clutch
when removing or installing the
clutch boss securing nut. Tool name/Part number How to use Illustration

1-17
CONTROL FUNCTIONS
CONTROL FUNCTIONS
ENGINE STOP SWITCH
The engine stop switch "1" is located
on the left handlebar. Continue push-
ing the engine stop switch till the en-
gine comes to a stop.
CLUTCH LEVER
The clutch lever "1" is located on the
left handlebar; it disengages or en-
gages the clutch. Pull the clutch lever
to the handlebar to disengage the
clutch, and release the lever to en-
gage the clutch. The lever should be
pulled rapidly and released slowly for
smooth starts.
SHIFT PEDAL
The gear ratios of the constant-mesh
5 speed transmission are ideally
spaced. The gears can be shifted by
using the shift pedal "1" on the left
side of the engine.
KICKSTARTER CRANK
Rotate the kickstarter crank "1" away
from the engine. Push the starter
down lightly with your foot until the
gears engage, then kick smoothly
and forcefully to start the engine. This
model has a primary kickstarter crank
so the engine can be started in any
gear if the clutch is disengaged. In
normal practices, however, shift to
neutral before starting.THROTTLE GRIP
The throttle grip "1" is located on the
right handlebar; it accelerates or de-
celerates the engine. For accelera-
tion, turn the grip toward you; for
deceleration, turn it away from you.
FRONT BRAKE LEVER
The front brake lever "1" is located on
the right handlebar. Pull it toward the
handlebar to activate the front brake.
REAR BRAKE PEDAL
The rear brake pedal "1" is located on
the right side of the machine. Press
down on the brake pedal to activate
the rear brake.
STARTER KNOB/IDLE SCREW
The starter knob/idle screw "1" is
used when starting a cold engine.
Pull the starter knob/idle screw out to
open the circuit for starting. When the
engine has warmed up, push it in to
close the circuit.
STARTING AND BREAK-IN
FUEL
Always use the recommended fuel as
stated below. Also, be sure to use
new gasoline the day of a race.
Use only unleaded gasoline. The
use of leaded gasoline will cause
severe damage to the engine inter-
nal parts such as valves, piston
rings, and exhaust system, etc.
Your Yamaha engine has been de-
signed to use premium unleaded gas-
oline with a pump octane number
[(R+M)/2] of 91 or higher, or a re-
search octane number of 95 or high-
er. If knocking (or pinging) occurs,
use a gasoline of a different brand.
• For refueling, be sure to stop the
engine and use enough care not
to spill any fuel. Also be sure to
avoid refueling close to a fire.
• Refuel after the engine, exhaust
pipe, etc. have cooled off.
Gasohol (For USA and Canada)
There are two types of gasohol: gas-
ohol containing ethanol and that con-
taining methanol. Gasohol containing
ethanol can be used if the ethanol
content does not exceed 10%. Gaso-
hol containing methanol is not recom-
mended by Yamaha because it can
cause damage to the fuel system or
vehicle performance problems.
HANDLING NOTE
Never start or run the engine in a
closed area. The exhaust fumes
are poisonous; they can cause
loss of consciousness and death
in a very short time. Always oper-
ate the machine in a well-ventilated
area.
Recommended fuel:
Premium unleaded
gasoline only

2-2
GENERAL SPECIFICATIONS
Fuel:
Type Premium unleaded gasoline only
Tank capacity 6.2 L (1.40 Imp gal, 1.64 US gal)
Throttle body:
Type 30RA
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7–0.8 mm (0.028–0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 2.652 (61/23)
Final drive Chain
Secondary reduction ratio 3.692 (48/13) (For USA, CDN)
3.769 (49/13) (For EUROPE, AUS, NZ, ZA)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio:
1st 1.929 (27/14)
2nd 1.533 (23/15)
3rd 1.278 (23/18)
4th 1.091 (24/22)
5th 0.952 (20/21)
Chassis: USA, CDN EUROPE AUS, NZ, ZA
Frame type Semi double cra-
dle←←
Caster angle 26.95° 26.80° 27.00°
Trail 118 mm (4.65 in) 117 mm (4.61 in) 120 mm (4.72 in)
Tire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 120/80-19 63M (For USA, CDN, AUS, NZ, ZA)
110/90-19 62M (For EUROPE)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper

2-7
MAINTENANCE SPECIFICATIONS
Crankshaft:
Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ----
Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002
in)
Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02
in)
Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08
in)
Balancer:
Balancer drive method Gear ----
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 ----
Fuel pump:
Fuel pressure 324 kPa (3.24 kg/cm
2, 46.1 psi) ----
Fuel injector:----
Model/manufacturer 1010/DENSO ----
Throttle body:----
I. D. mark 33D1 00 ----
Manufacturer KEIHIN ----Item Standard Limit

2-10
MAINTENANCE SPECIFICATIONS
ELECTRICALFront disc brake:
Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 9.52 mm (0.375 in) ----
Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height (vertical height above footrest
top)0 mm (0 in) ----
Clutch lever free play (lever end) 7–12 mm (0.28–0.47 in) ----
Throttle grip free play3–5 mm (0.12–0.20 in) ---- Item Standard Limit
Item Standard Limit
Ignition system:
Advancer type Electrical ----
AC magneto:
Magneto-model (stator)/manufacturer 33D00/YAMAHA ----
Stator coil resistance (color) 0.60–0.90 Ωat 20 °C (68 °F) (White–
White)----
Crankshaft position sensor resistance (color) 248–372 Ωat 20 °C (68 °F) (Gray–Black) ----
ECU-model/manufacturer 33D7 (USA, CDN) ----
33D4 (EUROPE) ----
33D6 (AUS, NZ, ZA) ----
Ignition coil:
Model/manufacturer F6T541/MITSUBISHI ----
Minimum spark gap 6.0 mm (0.24 in) ----
Primary coil resistance 3.57–4.83 Ωat 20 °C (68 °F) ----
Secondary coil resistance 10.71–14.49 kΩat 20 °C (68 °F) ----
Coolant temperature sensor:
Coolant temperature sensor resistance 2.51–2.78 kΩat 20 °C (68 °F) ----
210–220 Ωat 100 °C (212 °F) ----

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