2014 YAMAHA YZ450F brake

TORQUE-CHECK POINTS
1-26
TIP
Concerning the tightening torque, refer to “TIGHTENING TORQUES” on page 2-13.
Plastic coverTightening of number plate
Tightening of front fender
Tightening of fork leg protector
Tightening of air scoop
Left cover to rear frame
Tightening of side cover
Tightening of rear fender
Tightening of mud flap
Tightening of rear brake disc cov-
er
Tightening of rear brake caliper
cover

CHASSIS SPECIFICATIONS
2-8
EAS1SL1054
CHASSIS SPECIFICATIONS
Chassis
Frame type Semi double cradle
Caster angle 27.08 ° (USA) (CAN)
27.50 ° (EUR)
27.67 ° (JPN)
27.58 ° (AUS) (NZL) (ZAF)
Trail 120 mm (4.7 in) (USA) (CAN)
122 mm (4.8 in) (EUR)
124 mm (4.9 in) (JPN) (AUS) (NZL) (ZAF)
Front wheel
Wheel type Spoke wheel
Rim size 21  1.60
Rim material Aluminum
Wheel travel 310.0 mm (12.20 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Rear wheel
Wheel type Spoke wheel
Rim size 19  2.15
Rim material Aluminum
Wheel travel 315.0 mm (12.40 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Wheel axle bending limit 0.50 mm (0.02 in)
Front tire
Type With tube
Size 80/100-21 51M
Manufacturer/model DUNLOP/MX51FA (USA) (CAN)
PIRELLI/MID SOFT 32 (EUR)
BRIDGESTONE/M601 (JPN)
DUNLOP/MX51FA (AUS) (NZL) (ZAF)
Rear tire
Type With tube
Size 120/80-19 63M (USA) (CAN)
110/90-19 62M (EUR) (JPN)
120/80-19 63M (AUS) (NZL) (ZAF)
Manufacturer/model DUNLOP/MX51 (USA) (CAN)
PIRELLI/MID SOFT 32 (EUR)
BRIDGESTONE/M602 (JPN)
DUNLOP/MX51 (AUS) (NZL) (ZAF)
Tire air pressure (measured on cold tires)
Front 100 kPa (1.00 kgf/cm2, 15 psi)
Rear 100 kPa (1.00 kgf/cm2, 15 psi)
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter  thickness 250.0  3.0 mm (9.84  0.12 in)

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
2-18
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

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

LUBRICATION POINTS AND LUBRICANT TYPES
2-24
Rear brake caliper pin bolt and boot
Rear brake master cylinder push rod end
Rear brake master cylinder kit
Lubrication point Lubricant types
S
S

CABLE ROUTING DIAGRAM
2-38
1. Throttle cable
2. Clutch cable3. Engine stop switch lead
4. Cable guide
5. Head pipe6. Front brake hose
7. Brake hose guide
8. Number plate
A. Number plate band
B. Pass the clutch cable to the rear of the number
plate band.
C. Clamp the engine stop switch lead to the handle-bar by the plastic band. Do not cut the end of the
plastic band.
D. Pass the engine stop switch lead between the
head pipe and the cable guide.
E. Pass the front brake hose to the front of the num-ber plate.
F. 40°±10°G. Vertical direction
H. Pass the engine stop switch lead under the han-dlebar.
I. Pass the clutch cable to the guide in the number
plate.