2016 YAMAHA YZ450F engine oil

LUBRICATION POINTS AND LUBRICANT TYPES
2-20
EASB111058
LUBRICATION POINTS AND LUBRICANT TYPES
EASB111059ENGINE
Lubrication point Lubricant types
Oil seal lips
Bearing
O-ring
Camshaft cap bolt threads and contacting surface
Cylinder head bolt threads, seats, washers
Valve stems
Valve stem ends
Valve lifter outer surface
Camshaft lobe and journal
Valve lifter top surface
Crankshaft journal
Crankshaft big end thrust surfaces
Piston outer surface
Piston pin outer surface
Decompression system moving parts
Water pump impeller shaft
Oil pump rotors (inner and outer)
Oil passage gasket
Oil pump shaft
Kick gear and ratchet wheel
Kick shaft
Kick idle gear inner surface
Ratchet wheel and ratchet wheel guide contacting portion
Primary drive gear nut threads and contacting surface
Clutch boss nut threads and contacting surface
Primary driven gear inner surface and end surface
Clutch push rod washer
Clutch push rod 1 outer surface
Clutch push rod 1 thrust surface
Clutch push rod 2 outer surface
Push lever shaft outer surface
Transmission gear inner surface (wheel and pinion) and collar
Transmission gears (shift fork groove)
Shift cam grooves
Shift fork and shift fork guide outer surface
Shift shaft and collar
Shift lever assembly moving parts
LS
E
LS
E
M
M
M
E
M
E
M
E
E
M
E
E
E
LS
E
M
E
E
M
E
E
E
E
E
E
E
E
M
E
E
E
E
E

3
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS.......................................................................... 3-1
MAINTENANCE INTERVALS .................................................................... 3-1
PRE-OPERATION INSPECTION AND MAINTENANCE................................. 3-7
GENERAL INSPECTION AND MAINTENANCE........................................ 3-7
ENGINE............................................................................................................ 3-8
CHECKING THE COOLANT LEVEL .......................................................... 3-8
CHECKING THE COOLING SYSTEM ....................................................... 3-8
CHANGING THE COOLANT...................................................................... 3-8
CHECKING THE RADIATOR CAP ............................................................ 3-9
CHECKING THE RADIATOR CAP VALVE OPENING PRESSURE ......... 3-9
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-10
ADJUSTING THE CLUTCH LEVER POSITION ...................................... 3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-11
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-11
LUBRICATING THE THROTTLE CABLE ................................................ 3-12
CLEANING THE AIR FILTER ELEMENT................................................. 3-12
CHECKING THE THROTTLE BODY JOINT ............................................ 3-13
CHECKING THE BREATHER HOSES .................................................... 3-13
CHECKING THE EXHAUST SYSTEM..................................................... 3-14
CHECKING THE FUEL LINE ................................................................... 3-14
CHECKING THE ENGINE OIL LEVEL..................................................... 3-14
CHANGING THE ENGINE OIL ................................................................ 3-15
ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-16
ADJUSTING THE VALVE CLEARANCE ................................................. 3-17
CHASSIS........................................................................................................ 3-22
BLEEDING THE BRAKE SYSTEM .......................................................... 3-22
CHECKING THE BRAKE HOSE .............................................................. 3-23
ADJUSTING THE FRONT BRAKE .......................................................... 3-23
ADJUSTING THE REAR BRAKE ............................................................. 3-24
CHECKING THE FRONT BRAKE PADS ................................................. 3-24
CHECKING THE REAR BRAKE PADS ................................................... 3-26
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-27
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-27
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-28
CHECKING THE FRONT FORK LEGS ................................................... 3-29
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-29
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................ 3-29
AIR BLEEDING FROM FRONT FORK .................................................... 3-30
ADJUSTING THE FRONT FORK LEGS .................................................. 3-30
CHECKING THE SWINGARM OPERATION ........................................... 3-31
CHECKING THE REAR SUSPENSION ................................................... 3-31
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-31
CHECKING THE TIRES ........................................................................... 3-34
CHECKING AND TIGHTENING THE SPOKES ....................................... 3-34
CHECKING THE WHEELS ...................................................................... 3-34

MAINTENANCE INTERVALS
3-2
PISTON RING
Inspect Check the end gap of the pis-
ton ring.
Replace Replace the piston, piston pin,
piston pin clip, and piston ring
all as a set.
PISTON PIN
Inspect
Replace Replace the piston, piston pin,
piston pin clip, and piston ring
all as a set.
CYLINDER HEAD Check the coolant passages
for corrosion.
Inspect carbon deposits and
eliminate them.
Inspect and clean Check for warpage, and re-
place the gasket.
CYLINDER
Inspect and clean Inspect score marks.
Replace Inspect wear.
ENGINE OIL
Inspect Check the engine oil amount.
Replace
OIL FILTER ELE-
MENT
Replace
OIL STRAINER
Clean
CLUTCH
Inspect and adjust Inspect housing, friction plate,
clutch plate and spring.
Replace
TRANSMISSION
Inspect
Replace bearings
SHIFT FORK, SHIFT
CAM, GUIDE BAR
Inspect Inspect wear.ITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks

MAINTENANCE INTERVALS
3-3
NUT (ROTOR)
Retighten Check for tightening torques.
EXHAUST PIPE, SI-
LENCER, PROTEC-
TOR
Inspect and re-
tightenCheck for exhaust leaks, and
tightening torques.
Clean
Replace fiver ** When the exhaust sound be-
comes louder or when a per-
formance drop is felt.
CRANKSHAFT
Inspect and clean
THROTTLE BODY
Inspect
AIR FILTER
Clean and lubri-
cateUse foam air-filter oil or equiv-
alent oil.
Replace
SPARK PLUG
Inspect and clean Check the electrodes and the
terminals for wear.
Replace
COOLING SYSTEM
Check coolant lev-
el and leakage
Check radiator cap
operationUse the radiator cap tester for
a checkup.
Check radiator cap
attached
Change the cool-
antEvery two years
Inspect hoses
ENGINE GUARD
Replace Breakage
FRAME
Clean and inspectITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks

PRE-OPERATION INSPECTION AND MAINTENANCE
3-7
EASB111066
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EASB111067GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.ITEM inspect Page
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.3-8 – 10
FuelCheck that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage.1-21
Engine oilCheck that the oil level is correct. Check the crank-
case and oil line for leakage.3-14 – 16
Gear shifter and clutchCheck that gears can be shifted correctly in order and
that the clutch operates smoothly.3-10 – 11
Throttle grip/HousingCheck that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary.3-11 – 12
BrakesCheck the play of front brake and effect of front and
rear brake.3-22 – 28
Drive chainCheck drive chain slack and alignment. Check that
the drive chain is lubricated properly.3-28 – 29
4-66 – 67
WheelsCheck for excessive wear and tire pressure. Check
for loose spokes and have no excessive play.3-34
SteeringCheck that the handlebar can be turned smoothly and
have no excessive play.3-35 – 36
Front forks and rear
shock absorberCheck that they operate smoothly and there is no oil
leakage.3-29 – 33
Cables (wires)Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.—
Exhaust pipeCheck that the exhaust pipe is tightly mounted and
has no cracks.3-14
Rear wheel sprocketCheck that the rear wheel sprocket tightening bolt is
not loose.4-8 – 9
Lubrication Check for smooth operation. Lubricate if necessary. 3-12, 3-36
Bolts and nutsCheck the chassis and engine for loose bolts and
nuts.1-24 – 25
Lead connectorsCheck that the AC magneto, ECU and ignition coil are
connected tightly.1-10 – 12
SettingsIs the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?10-1 – 8

ENGINE
3-13
3. Wash:
• Air filter element
EWA
WARNING
Do not use gasoline or organic (acid/alka-
line) volatile oil for washing.
TIP
After washing the element with air filter cleaner
or kerosene, squeeze and dry it completely.
ECA
NOTICE
Do not twist the element when squeezing
the element.
4. Check:
• Air filter element
Damage  Replace.
5. Foam-air-filter oil or equivalent oil to the ele-
ment
TIP
Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:
• Air filter guide “1” (to the air filter element)
• Air filter element “2”
• Air filter mounting bolt “3”7. Install:
• Air filter case cover “1”
TIP
Align the air filter case cover groove “a” with the
air filter case edge “b”.
8. Install:
• Fuel tank cap cover
EASB111080CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body joint
Refer to “CHECKING THE THROTTLE
BODY JOINT” on page 7-8.
EASB111081CHECKING THE BREATHER HOSES
1. Check:
• Breather hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
ECA14920
NOTICE
Make sure the cylinder head breather hose
is routed correctly. Oil application quantify
50 g
Air filter mounting bolt
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
13
2
T R..
31
2
a
b 1
1

ENGINE
3-14
EASB111082CHECKING THE EXHAUST SYSTEM
1. Remove:
• Exhaust pipe protector
2. Check:
• Exhaust pipe 1
• Exhaust pipe 2
• Silencer
Crack/damage  Replace.
Refer to “ENGINE REMOVAL” on page 5-1.
• Exhaust gas
Leaks  Replace the gasket.
Refer to “ENGINE REMOVAL” on page 5-1.
3. Check:
• Tightening torques
4. Install:
• Exhaust pipe protectorEASB111083CHECKING THE FUEL LINE
1. Remove:
• Seat
• Side cover (left/right)
• Air scoop (left/right)
Refer to “GENERAL CHASSIS” on page 4-
1.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Check:
• Fuel hose “1”
Crack/damage  Replace.
Loose connection  Connect properly.
3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Air scoop (left/right)
• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 4-
1.
EASB111084CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle upright on a level surface.
2. Start the engine, warm this up for 2–3 min-
utes, and then stop the engine and wait
about 1 minute.
3. Check:
• Oil level
Make sure that the engine oil level is above
the minimum level mark “a” shown for the oil
level check window “1”, and that the engine
oil does not come out by removing the oil
check bolt “2”.
The minimum level mark “a” or below  Add
the engine oil until its level exceeds the min-
imum level mark “a”.
Engine oil coming out of the oil check bolt 
Drain it until its last drop is out. Exhaust pipe bolt 1 and nut “1”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe 1 and exhaust pipe
2 bolt “2”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Exhaust pipe 2 and silencer bolt
“3”
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Silencer and silencer bracket bolt
“4”
30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe protector screw
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
T R..
2
1
4
3
T R..
1

ENGINE
3-15
ECA33DD018
NOTICE
• Since engine oil also lubricates the clutch,
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives.
• Do not allow foreign material to enter the
crankcase.
EASB111085CHANGING THE ENGINE OIL
Stand the vehicle upright on a level surface.
1. Start the engine, warm this up for several
minutes, and then stop the engine and wait
about 5 minutes.
2. Place an oil pan under the drain bolt.
3. Remove:
• Oil filler cap “1”
• Drain bolt (with gasket) “2”4. If the oil filter element is also to be replaced,
perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filter element cover “1” and
oil filter element “2”.
b. Replace the O-rings “3”.
c. Install the new oil filter element and the oil fil-
ter element cover.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. To check the oil strainer, perform the follow-
ing procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil strainer “1”.
b. Check the oil strainer.
Damage  Replace.
Clogging due to dirt  Wash with kerosene.
c. Replace the O-rings “2”. Recommended brand
YAMALUBE
Type
SAE 10W-40, SAE 10W-50, SAE
15W-40, SAE 20W-40 or SAE
20W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
12
a
Oil filter element cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
2
1
3
2
New
T R..