2016 YAMAHA YZ450F Owners Manual

CYLINDER HEAD
5-22
EASB111214REMOVING THE CYLINDER HEAD
1. Remove:
• Cylinder head bolts
TIP
• Loosen the bolts in the proper sequence as
shown.
• Loosen each bolt 1/2 of a turn at a time. After
fully loosening all the bolts, remove them.
•M6  35 mm (1.38 in): “1” – “2”
• M10  149 mm (5.87 in): “3” – “6”
EASB111215CHECKING THE TIMING CHAIN GUIDE (IN-
TAKE SIDE)
1. Check:
• Timing chain guide (intake side)
Damage/wear  Replace.
EASB111216CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
TIP
Use a rounded scraper, not a sharp instrument,
in order not to damage or scratch the spark
plug bore threads.2. Check:
• Cylinder head
Damage/scratches  Replace.
TIP
When replacing the cylinder head, replace also
the valve.
Refer to “CHECKING THE VALVE SEATS” on
page 5-28.
• Cylinder head coolant passages
Mineral deposits/rust  Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification  Resurface the cylin-
der head.
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a. Place a straightedge and a thickness gauge
across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400–600 grit wet sandpaper on a
surface plate, and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, turn the cylinder
head several times.
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61
2
35
4 x2 x4FWD
Warpage limit
0.05 mm (0.0020 in)

CYLINDER HEAD
5-23
EASB111217INSTALLING THE CYLINDER HEAD
1. Install:
• Timing chain guide (intake side) “1”
• Dowel pins
• Cylinder head gasket
• Dowel pins
TIP
While pulling up the timing chain, install the tim-
ing chain guide (intake side) and the cylinder
head.
2. Install:
• Cylinder head
• Cylinder head
•Bolt “3”
TIP
Tighten the bolts using the following procedure.
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a. Wash the threads and contact surfaces of
the bolts, the contact surfaces of the wash-
ers, the contact surface of the cylinder head,
and the threads of the crankcase.
b. Apply molybdenum disulfide grease to the
threads and contact surfaces of the bolts
and to both contact surfaces of the washers
“1”.
c. Install the washers and the bolts.
d. Tighten the bolts to the specified torque in
two or three steps in the proper tightening
sequence as shown.e. Remove the bolts.
f. Again apply molybdenum disulfide grease to
the threads and contact surfaces of the bolts
and to both contact surfaces of the washers.
g. Retighten the bolts.
TIP
Tighten the bolts to the specified torque in two
or three steps in the proper tightening se-
quence as shown.
h. Put a mark on the corner “1” of the bolt (cyl-
inder head) and the cylinder head “2” as
shown.
New
12
2 4
3
1
3 22
Bolts “1”–“4”
1st
30 Nm (3.0 m·kgf, 22 ft·lbf)
Bolts “1”–“4”
2nd
20 Nm (2.0 m·kgf, 14 ft·lbf)
T R..
15
6
42
3 FWD
x2 x4
T R..
1
2

CYLINDER HEAD
5-24
i. Retighten the cylinder head mounting bolts
150° in the proper tightening sequence.
TIP
Tighten the bolts in two steps (90° and 60°) to
reach the specified angle in the proper tighten-
ing sequence.
j. Tighten the bolts to the specified torque.
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Bolts “1”–“4”
Final
Specified angle 150°
Bolt “5”, “6”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T R..
T R..

VALVES AND VALVE SPRINGS
5-25
EASB111218
VALVES AND VALVE SPRINGS
Removing the valves and valve springs
Order Part name Q’ty Remarks
Cylinder headRefer to “CYLINDER HEAD” on page 5-20.
1 Valve lifter 4
2 Adjusting pad 4
3 Valve cotter 8
4 Valve spring retainer 4
5 Valve spring 4
6 Valve stem seal 4
7 Valve spring seat 4
8 Intake valve 2
9 Exhaust valve 2
For installation, reverse the removal proce-
dure.

VALVES AND VALVE SPRINGS
5-26
EASB111219REMOVING THE VALVES
TIP
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure that the valves are properly
sealed.
1. Remove:
• Valve lifter “1”
• Adjusting pad “2”
TIP
• Place a cloth in the timing chain space to pre-
vent adjusting pads from falling into the crank-
case.
• Make a note of the positions of valve lifters
and adjusting pads so that they can be rein-
stalled in their original places.2. Check:
• Valve sealing
Leakage at the valve seat  Check the
valve face, the valve seat, and the valve seat
contact width.
Refer to “CHECKING THE VALVE SEATS”
on page 5-28.
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a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves are properly sealed.
TIP
Check that there are no kerosene leaks from
the valve seat “1”.
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3. Remove:
• Valve cotter “1”
TIP
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
“2” and the valve spring compressor adapter
“3”. Valve lapper
90890-04101
Valve lapping tool
YM-A8998
1
2
Valve spring compressor
90890-04019
YM-04019
Valve spring compressor adapter
22 mm
90890-04108
YM-04108
a1
a

VALVES AND VALVE SPRINGS
5-27
4. Remove:
• Valve spring retainer “1”
• Valve spring “2”
•Valve “3”
• Valve stem seat “4”
• Valve spring seat “5”
TIP
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EASB111220CHECKING THE VALVES AND VALVE
GUIDES
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification  Replace the valve
guide.2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100°C (212°F) in an oven.
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a. Remove the valve guide with the valve guide
remover “1”.
b. Install the new valve guide with the valve
guide installer “2” and the valve guide re-
mover “1”. Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.020–0.047 mm (0.0008–0.0019
in)
Limit
0.100 mm (0.0039 in)
1
2
4
5
3
Valve guide installation height “a”
Intake
15.1–15.5 mm (0.59–0.61 in)
Exhaust
12.2–12.6 mm (0.48–0.50 in)
1

VALVES AND VALVE SPRINGS
5-28
c. After installing the valve guide, expand the
hole in the valve guide with the valve guide
reamer “3” to obtain the proper valve-stem-
to-valve-guide clearance.
TIP
After replacing the valve guide, reface the valve
seat.
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3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear  Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than
the body of the valve stem  Replace the
valve.
5. Measure:
• Valve margin thickness “a”
Out of specification  Replace the valve.6. Measure:
• Valve stem runout
Out of specification  Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
EASB111221CHECKING THE VALVE SEATS
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
Pitting/wear  Replace the cylinder head.
3. Measure:
• Valve seat contact width “a”
Out of specification  Replace the cylinder
head. Valve guide remover & installer
set (ø5.5)
90890-04016
Valve guide remover (5.5 mm)
YM-01122
Valve guide installer (5.5 mm)
YM-04015
Valve guide reamer (5.5 mm)
YM-01196
Valve margin thickness (intake)
1.20 mm (0.0472 in)
Valve margin thickness (exhaust)
0.85 mm (0.0335 in)
Valve stem runout
0.010 mm (0.0004 in)
Valve seat contact width (intake)
0.90–1.10 mm (0.0354–0.0433 in)
Valve seat contact width (ex-
haust)
0.90–1.10 mm (0.0354–0.0433 in)

VALVES AND VALVE SPRINGS
5-29
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a. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat contact width “c”.
TIP
Where the valve seat and the valve face are in
contact with each other, the blueing will have
been removed.
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4. Lap:
• Valve face
• Valve seat
ECA
NOTICE
This model uses titanium intake and ex-
haust valves.
Do not use the valves used for lapping the
valve seat. Always replace the valves used
for lapping with new ones.
TIP
• When replacing the cylinder head, replace
also the valves with new ones without them.
• When replacing the valves or the valve
guides, use new valves to lap the valve seats,
and then replace them with new valves.
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a. Apply a coarse lapping compound “a” to the
valve face.
ECA
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and the
valve seat are evenly polished, then clean
off all of the lapping compound.
TIP
While turning the valve lapper, tap and lap the
valve seat.
c