2016 YAMAHA YZ450F Owners Manual

SHIFT SHAFT
5-54
4. Tighten:
• Shift guide bolt “1”
EASB111262INSTALLING THE SHIFT SHAFT
1. Install:
• Roller “1”
• Stopper lever “2” (to shift shaft)
• Collar “3” (to shift shaft)
• Shift shaft “4”
TIP
Apply the engine oil on the roller and shift shaft.
2. Install:
• Oil seal
EASB111263INSTALLING THE SHIFT PEDAL
1. Install:
• Shift pedal
• Shift pedal
TIP
Align the punch mark “a” on the shift shaft with
the punch mark “b” in the shift pedal.Shift guide bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
Shift pedal bolt
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T R..
1 1
LT
E
E
1
23
4
New
T R..
a
12b

OIL PUMP AND BALANCER GEAR
5-55
EASB111264
OIL PUMP AND BALANCER GEAR
Removing the oil pump
Order Part name Q’ty Remarks
Primary driven gear Refer to “CLUTCH” on page 5-38.
Right crankcase cover Refer to “CLUTCH” on page 5-38.
1 Oil pump assembly 1
2 Oil pump cover 1
3 Outer rotor 1
4 Dowel pin 1
5 Inner rotor 1
6 Oil pump drive shaft 1
7 Rotor housing 1
For installation, reverse the removal proce-
dure.
2.0 Nm (0.20 mkgf, 1.4 ftIbf)T.R
.
5 Nm (0.5 mkgf, 3.6 ftIbf)T.R
.
LT
E
3
2
1
4
5
7
6

OIL PUMP AND BALANCER GEAR
5-56
Removing the balancer
Order Part name Q’ty Remarks
Primary driven gear Refer to “CLUTCH” on page 5-38.
Right crankcase cover Refer to “CLUTCH” on page 5-38.
Stator Refer to “AC MAGNETO” on page 5-61.
1 Nut (balancer) 1
2 Nut (primary drive gear) 1
3 Nut (balancer shaft driven gear) 1
4 Lock washer 1
5Balancer 1
6 Straight key 1
7 Conical washer 1
8 Primary drive gear 1
9 Balancer shaft drive gear 1
10 Lock washer 1
11 Balancer weight gear 1
For installation, reverse the removal proce-
dure.
45 Nm (4.5 mkgf, 33 ftIbf)T.R
.
100 Nm (10 mkgf, 72 ftlbf)T.R.
50 Nm (5.0 mkgf, 36 ftIbf)T.R
.
New

OIL PUMP AND BALANCER GEAR
5-57
EASB111265REMOVING THE BALANCER
1. Straighten the lock washer tab.
2. Loosen:
• Balancer nut “1”
• Primary drive gear nut “2”
• Balancer weight gear nut “3”
TIP
Place an aluminum plate “a” between the teeth
of the balancer drive gear “4” and balancer
weight gear “5”.
EASB111266CHECKING THE PRIMARY DRIVE GEAR,
BALANCER SHAFT DRIVE GEAR, AND
BALANCER WEIGHT GEAR
1. Check:
• Primary drive gear “1”
• Balancer shaft drive gear “2”
• Balancer weight gear “3”
Wear/damage  Replace.
EASB111267CHECKING THE BALANCER
1. Check:
•Balancer
Crack/damage  Replace.
EASB111268CHECKING THE OIL PUMP
1. Check:
• Oil pump drive gear
• Oil pump driven gear
• Oil pump housing
• Oil pump housing cover
Cracks/damage/wear  Replace the defec-
tive part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification  Replace the oil pump.
1
5
4
2
a
43
a
5

OIL PUMP AND BALANCER GEAR
5-58
3. Check:
• Oil pump operation
Rough movement  Repeat steps (1) and
(2) or replace the defective part(s).
EASB111269
ASSEMBLING THE OIL PUMP
1. Install:
• Oil pump drive shaft “1”
• Inner rotor “2”
• Dowel pin “3”
TIP
• Apply the engine oil on the oil pump drive
shaft and inner rotor.
• Fit the dowel pin into the groove in the inner
rotor.
2. Install:
• Outer rotor “1”
TIP
Apply the engine oil on the outer rotor.
3. Install:
• Oil pump cover “1”
• Oil pump cover screw “2” Inner-rotor-to-outer-rotor-tip
clearance
Less than 0.150 mm (0.0059 in)
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit
0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-
outer-rotor
clearance
0.06–0.11 mm (0.0024–0.0043 in)
Limit
0.17 mm (0.0067 in)
1. Inner rotor
2. Outer rotor
3. Oil pump housing
b
a 1
2
3
c
Oil pump cover screw
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
21
3
1
E
T R..
2
1

OIL PUMP AND BALANCER GEAR
5-59
EASB111270INSTALLING THE OIL PUMP AND BALANC-
ER GEAR
1. Install:
• Oil pump assembly “1”
• Oil pump assembly bolt “2”
ECA1DX1023
NOTICE
After tightening the bolts, make sure that
the oil pump turns smoothly.
2. Install:
• Balancer weight gear “1”
TIP
Install the balancer weight gear and balancer
shaft with their lower splines “a” aligning with
each other.
3. Install:
• Balancer drive gear “1”
TIP
• Align the punched mark “a” on the balancer
drive gear with the punched mark “b” on the
balancer weight gear.
• Install the balancer drive gear and crankshaft
with the lower splines “c” aligning with each
other.4. Install:
• Lock washer “1”
• Balancer weight gear nut “2”
• Primary drive gear “3”
• Conical washer “4”
• Primary drive gear nut “5”
• Straight key “6”
•Balancer “7”
• Lock washer “8”
• Balancer nut “9”
TIP
• Apply engine oil to the contact surface and
threaded portion of the primary drive gear nut.
• Apply engine oil to the contact surfaces of the
conical washer.
• Place an aluminum plate “a” between the
teeth of the balancer drive gear “10” and bal-
ancer weight gear “11”.
• Install the conical washer with its convex sur-
face “b” outward. Oil pump assembly bolt
5 Nm (0.5 m·kgf, 3.6 ft·lbf)
LOCTITE®
T R..
1
2
LT
Balancer weight gear nut
50 Nm (5.0 m·kgf, 36 ft·lbf)
Primary drive gear nut
100 Nm (10 m·kgf, 72 ft·lbf)
Balancer nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
New
T R..
New
T R..
New
T R..
1
2 11
10
a

OIL PUMP AND BALANCER GEAR
5-60
5. Bend the lock washer tab.
3 45
1011
a
b
3

AC MAGNETO
5-61
EASB111271
AC MAGNETO
Removing the AC magneto
Order Part name Q’ty Remarks
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-15.
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left) Refer to “GENERAL CHASSIS” on page 4-1.
1 AC magneto coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Shift pedal 1
4 Left crankcase cover 1
5 Gaskets 1
6 Dowel pin 2
7Holder 1
8 Stator assembly 1
9 Rotor 1
10 Woodruff key 1
For installation, reverse the removal proce-
dure.
110
2
4 7 5 8 3
96
12 Nm (1.2 m kgf, 8.7 ft Ibf)T.R.
8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
8 Nm (0.8 m kgf, 5.8 ft Ibf)T.R.
65 Nm (6.5 m kgf, 47 ft Ibf)T.R.
New
LT
6
LT
LT
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.