2014 YAMAHA YZ450F Front

CHASSIS SPECIFICATIONS
2-9
Brake disc thickness limit 2.5 mm (0.10 in)
Brake pad lining thickness (inner) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 4.4 mm (0.17 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 9.52 mm (0.37 in)
Caliper cylinder inside diameter 22.65 mm  2 (0.89 in  2)
Recommended brake fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Rear disc brake
Disc outside diameter  thickness 245.0  4.0 mm (9.65  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Brake pad lining thickness (outer) 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm  1 (1.00 in  1)
Recommended fluid DOT 4
Steering
Steering bearing type Taper roller bearing
Center to lock angle (left) 43.0 °
Center to lock angle (right) 43.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 310.0 mm (12.20 in)
Fork spring free length 497.0 mm (19.57 in)
Limit 492.0 mm (19.37 in)
Installed length 497.0 mm (19.57 in)
Spring rate K1 4.90 N/mm (0.50 kgf/mm, 27.98 lbf/in) (USA) 
(CAN)
4.70 N/mm (0.48 kgf/mm, 26.84 lbf/in) (EUR) 
(JPN) (AUS) (NZL) (ZAF)
Spring stroke K1 0.0–310.0 mm (0.00–12.20 in)
Inner tube outer diameter 48.0 mm (1.89 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available Yes
Recommended oil Suspension oil S1
Standard oil amount 531.0 cm3 (17.95 US.oz, 18.73 Imp.oz) (USA) 
(CAN)
551.0 cm3 (18.63 US.oz, 19.43 Imp.oz) (EUR) 
(JPN) (AUS) (NZL) (ZAF)
Rebound damping adjusting positions
* Position in which the adjuster is turned in finger tight
Minimum 20 click (s) out*
Standard 8 click (s) out*
Maximum (hard) Fully turned in

TIGHTENING TORQUES
2-15
Air filter boltM6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air filter case cover bolt M6 3 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Air filter guide holder screw M5 8 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Air filter case cap screw M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Starter knob/Idle screw M12 1 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf)
Throttle cable nut (pull) M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle cable nut (return) M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Clutch cable adjuster and locknut M6 1 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf)
Clutch cable locknut (engine side) M8 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Exhaust pipe nut M6 3See TIP.
*2
Exhaust pipe protector screw M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe bracket bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Frame and silencer bolt (front) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Frame and silencer bolt (rear) M 8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe clamp bolt M8 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer body bolt M5 6 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Oil nozzle bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt M10 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Crankcase bolt M6 12 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Clutch cable holder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft end accessing screw M36 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing mark accessing screw M14 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Drive chain sprocket cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankcase bearing cover plate
screw M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase bearing cover plate
screw (crankshaft) M8 4 18 Nm (1.8 m·kgf, 13 ft·lbf) Crimp.
Clutch cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil level check window bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Left crankcase cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Right crankcase cover bolt M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil level check window bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Kick shaft ratchet wheel guide bolt M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Kick starter lever bolt M8 1 33 Nm (3.3 m·kgf, 24 ft·lbf)
Kick starter lever boss screw M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Primary drive gear nut M20 1 100 Nm (10 m·kgf, 72 ft·lbf)
Clutch spring bolt M6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch boss nut M20 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES RemarksLT
LT
LT
LT
LT
LT
LT

TIGHTENING TORQUES
2-18
CHASSIS TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEMThread
sizeQ’tyTIGHTENING TORQUESRemarks
Outer tube and upper bracket boltM8421 Nm (2.1 m·kgf, 15 ft·lbf)
Outer tube and lower bracket boltM8421 Nm (2.1 m·kgf, 15 ft·lbf)
Upper bracket and steering stem nutM241145 Nm (14.5 m·kgf, 105 ft·lbf)
Upper handlebar holder boltM8428 Nm (2.8 m·kgf, 20 ft·lbf)
Lower handlebar holder nutM10240 Nm (4.0 m·kgf, 29 ft·lbf)
Engine stop switch screwM310.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Lower ring nutM281See TIP.
Outer tube and damper assemblyM51230 Nm (3.0 m·kgf, 22 ft·lbf)
Inner tube and adjusterM22255 Nm (5.5 m·kgf, 40 ft·lbf)
Damper assembly and base valveM42228 Nm (2.8 m·kgf, 20 ft·lbf)
Damper assembly adjusterM12229 Nm (2.9 m·kgf, 21 ft·lbf)
Bleed screw (front fork) and base
valveM521.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Front fork protector boltM665 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front fork protector and brake hose
holder boltM629 Nm (0.9 m·kgf, 6.5 ft·lbf)
Throttle grip cap screwM523.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever holder boltM625 Nm (0.5 m·kgf, 3.6 ft·lbf)
Clutch lever nutM614.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Clutch lever position locknutM514.8 Nm (0.48 m·kgf, 3.5 ft·lbf)
Front brake master cylinder holder
boltM629 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake master cylinder reser-
voir cap screwM421.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Front brake lever pivot boltM616 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever pivot nutM616 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever position locknutM615 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front brake hose holder and lower
bracket boltM619 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake hose union boltM10230 Nm (3.0 m·kgf, 22 ft·lbf)
Front brake caliper boltM8228 Nm (2.8 m·kgf, 20 ft·lbf)
Front brake pad pinM10117 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake pad pin plugM1012.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front brake caliper bleed screwM816 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front wheel axle nutM181115 Nm (11.5 m·kgf, 83 ft·lbf)
Front wheel axle pinch boltM8421 Nm (2.1 m·kgf, 15 ft·lbf)
Front brake disc boltM6612 Nm (1.2 m·kgf, 8.7 ft·lbf)
LT
LT

TIGHTENING TORQUES
2-19
Rear brake disc boltM6 6 14 Nm (1.4 m·kgf, 10 ft·lbf)
Footrest bracket bolt M10 4 55 Nm (5.5 m·kgf, 40 ft·lbf)
Rear brake pedal bolt M8 1 26 Nm (2.6 m·kgf, 19 ft·lbf)
Rear brake pedal position locknut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake master cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake master cylinder reservoir
cap bolt M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Rear brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear wheel axle nut M22 1 135 Nm (13.5 m·kgf, 98 ft·lbf)
Drive chain puller adjust bolt and
locknut M8 2 21 Nm (2.1 m·kgf, 15 ft·lbf)
Rear wheel sprocket nut M8 6 42 Nm (4.2 m·kgf, 30 ft·lbf)
Nipple (spoke) — 72 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear brake disc cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake caliper protector bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Engine mounting bolt (upper side) M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Engine mounting bolt (front side) M 10 1 59 Nm (5.9 m·kgf, 43 ft·lbf)
Engine mounting bolt (lower side) M 10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Engine bracket bolt (upper side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine bracket bolt (front side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Rear frame and frame bolt M8 4 32 Nm (3.2 m·kgf, 23 ft·lbf)
Engine guard bolt (right side) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft and nut M16 1 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear shock absorber assembly up-
per bolt M10 1 56 Nm (5.6 m·kgf, 41 ft·lbf)
Rear shock absorber assembly low-
er bolt M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Rear shock absorber locknut M60 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Relay arm bolt (swingarm side) M14 1 70 Nm (7.0 m·kgf, 51 ft·lbf)
Connecting arm bolt (relay arm side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (frame side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Swingarm and brake hose holder
screw M5 4 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Drive chain tensioner bolt (upper
side) M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Drive chain tensioner bolt (lower
side) M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Drive chain support bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES RemarksLT
LT

TIGHTENING TORQUES
2-20
TIP
1. First, tighten the lower ring nut approximately 38 Nm (3.8 m·kgf, 27 ft·lbf) by using the steering nut
wrench, then loosen the lower ring nut one turn.
2. Retighten the lower ring nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf).
Drive chain support nutM627 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain guide boltM534.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear frame and left cover boltM627 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (front side)M627 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (rear side)M619 Nm (0.9 m·kgf, 6.5 ft·lbf)
Fuel tank bracket bolt (front side)M647 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bracket bolt (rear side)M627 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump boltM564.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel inlet pipe screwM523.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Fuel tank cap cover boltM624.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Seat set bracket and fuel tank screwM617 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat boltM8222 Nm (2.2 m·kgf, 16 ft·lbf)
Left side cover boltM617 Nm (0.7 m·kgf, 5.1 ft·lbf)
Right side cover boltM627 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame and air scoop boltM627 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank and air scoop boltM627 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator guard and air scoop boltM647 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender boltM6410 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear fender bolt (front side)M637 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt (rear side)M6216 Nm (1.6 m·kgf, 12 ft·lbf)
Mud flap screw—21.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Number plate boltM617 Nm (0.7 m·kgf, 5.1 ft·lbf)
ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks

LUBRICATION POINTS AND LUBRICANT TYPES
2-23
CHASSIS
Lubrication pointLubricant types
Upper bearings (steering head)
Upper bearings and bearing race cover (steering head)
Lower bearings and oil seal lip (steering head)
Steering stem threads and nut contacting surface
Pivot shaft bearing
Swingarm pivot portion (collar side surface and thrust bearing)
Swingarm pivot portion (collar outer surface)
Swingarm pivot portion (oil seal lip)
Pivot shaft outer surface
Relay arm bearing and oil seal lip
Relay arm thrust washer surface (both sides)
Relay arm collar outer surface and bolt outer surface
Relay arm bolt threads (swingarm side)
Connecting arm bearing and oil seal lip
Connecting arm collar outer surface and bolt outer surface
Rear shock absorber assembly collar outer surface and dust seal lip (upper
side)
Rear shock absorber assembly bearing and dust seal lip (lower side)
Brake pedal pivot portion (O-ring and bolt outer surface)
Front wheel oil seal lip
Front wheel axle outer surface
Rear wheel oil seal lip
Rear wheel axle outer surface
Push rod contacting portion (front brake master cylinder)
Front brake lever bolt outer surface
Clutch lever sliding surface and bolt outer surface
Clutch lever position adjuster end
Clutch lever adjuster rubber lip
Clutch cable end (clutch lever side)
Tube guide (throttle grip) inner surface and throttle cable end
Front brake caliper piston
Front brake caliper piston seal
Front brake caliper dust seal
Front brake caliper pin bolt and boot
Front brake master cylinder push rod end
Front brake master cylinder kit
Rear brake caliper piston
Rear brake caliper piston seal
Rear brake caliper dust seal
LS
LS
LS
LS
M
M
M
M
M
M
M
M
M
M
M
M
M
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
LS
S
S
S
S

CABLE ROUTING DIAGRAM
2-34
1. Clutch cable
2. Throttle cable (pull)3. Throttle cable (return)
4. Cable holder
5. Engine stop switch lead6. Frame
7. Coupler for connecting optional part
8. Bracket9. Engine stop switch coupler
10. Rectifier/regulator coupler
11. Starter knob/idle screw12. Neutral switch lead
13. Crankcase cover
14. AC magneto lead15. Front engine bracket
16. Radiator hose
17. Coupler cover18. Rectifier/regulator lead
19. Tension arm
20. Main harness21. Tank rail
22. Radiator
23. Cylinder head breather hose24. Radiator breather hose
25. Down tube
26. Crankcase
A. Pass the engine stop switch lead between the
frame and the cable holder.
B. Pass the engine stop switch lead between the
coupler for connecting optional part and the
frame, where the main harness should face the
outside of the vehicle.
C. Insert the coupler for connecting optional part into
the connector, and fix it to the bracket.
D. Insert and fix the engine stop switch coupler to
the bracket.
E. Insert and fix the rectifier/regulator coupler to the
bracket.
F. Pass the AC magneto lead to the front of the ve-hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
G. 70 mm (2.76 in)
H. Bring the neutral switch lead into line with the
crankcase cover with no sag allowed.
I. Bring the AC magneto lead into line with the
clutch cable with no sag allowed.
J. Pass the neutral switch lead to the inside of the
front engine bracket (the side of the vehicle).
K. Clamp the clutch cable and the AC magneto lead
by the plastic locking tie. Regardless of the orien-tation of the lock on the plastic locking tie, cut the
end.
L. Pass the clutch cable with no downward sag al-lowed.
M. Bring the grommet of the clutch cable into contact
with the radiator hose, and pass it to the outside
of the neutral switch lead and the AC magneto
lead (the outside of the vehicle).
N. 40 mm (1.57 in)
O. Clamp the clutch cable, the AC magneto lead,
and the neutral switch lead by the plastic locking
tie. Make sure that they are clamped at the posi
-tioning tape in the clutch cable. Make the lock on
the plastic locking tie face the front of the vehicle,
and cut the end.
P. After connecting the neutral switch coupler, at-tach the coupler cover.Q. After connecting the AC magneto coupler, attach
the coupler cover.
R. Pass the rectifier/regulator lead to the inside of
the tension arm (the side of the vehicle).
S. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside of
the clutch cable (the side of the vehicle).
T. Pass the engine stop switch lead between the
coupler for connecting optional part and the tank
rail, with the lead on the main harness side facing
the top of the vehicle.
U. Pass the radiator breather hose between the
down tubes.
V. Clamp the radiator breather hose, above the en-gine bracket (front). Clamp the lock on the plastic
tie with it located outside the vehicle, and face the
end toward the front of the vehicle.
W. Clamp the clutch cable at the front of the lead (the
front of the vehicle).
X. Make the lock on the plastic locking tie face the
front of the vehicle, and insert the projection into
the hole in the frame. Cut the end of the plastic
locking tie.

CABLE ROUTING DIAGRAM
2-36
1. Bracket
2. Condenser3. Coolant temperature sensor
4. Coupler cover
5. Intake air temperature sensor coupler6. Intake air temperature sensor coupler
7. Radiator hoses
8. Radiator breather hose9. Joint coupler
10. Plate
11. Tension arm12. Throttle position sensor lead
13. Ground lead
14. Throttle position sensor coupler15. Radiator breather hose
16. Cylinder head breather hose
17. Engine guard18. Crankcase
19. Fuel pump coupler
20. Fuel hose21. Condenser lead
22. Fuel pump lead
23. Condenser coupler24. Ground lead terminal
25. Fuel tank
26. Damper27. Rear frame
28. Main harness
A. Insert the condenser into the bracket as far as it
will go.
B. Attach the coupler cover to the coolant tempera-ture sensor coupler.
C. Pass the radiator breather hose to the inside of
the radiator hose (the side of the vehicle).
D. Insert and fix the joint coupler to the plate. After
fixing it, attach the cover.
E. Pass the throttle position sensor lead to the out-side of the tension arm (the outside of the vehi-cle).
F. After connecting the throttle position sensor cou-pler, attach the cover.
G. Pass the radiator breather hose to the outside of
the tension arm and the throttle position sensor
lead (the outside of the vehicle), and to the inside
of the radiator hose (the side of the vehicle).
H. Pass the protector of the cylinder head breather
hose until it touches the holder.
I. Pass the cylinder head breather hose between
the engine guard and the crankcase.
J. Install the end of the cylinder head breather hose
with it facing downward.
K. After connecting the fuel pump coupler, attach
the coupler cover.
L. 55 mm (2.17 in) (seat load receiver)
M. Clamp the fuel hose and the fuel pump lead by
the holder. Make sure that the painted part on the
fuel hose is clamped, and face the lock on the
clamp toward the rear top of the vehicle.
N. Do not install the plastic locking tie to the seat
load receiver.
O. Make the lock on the plastic locking tie face the
front of the vehicle, and make the end face the
bottom of the vehicle. Do not cut the end.
P. Install the ground lead terminal between the plate
and the bolt.
Q. DetentR. Fix the ground lead terminal to the detent in the
plate. For the ground lead terminal, either side
will do.
S. Insert the projection on the plastic locking tie into
the hole in the rear frame.
T. Clamp the painted part on the fuel hose by the
plastic clamp. Make the lock on the plastic clamp
face the bottom of the vehicle, and cut the end.