2016 YAMAHA YZ450F oil
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REAR SHOCK ABSORBER ASSEMBLY
4-59
EASB111178REMOVING THE BEARING
1. Remove:
• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer
race and remove the stopper ring.
2. Remove:
• Upper bearing “1”
TIP
Remove the bearing by pressing its outer race.
3. Remove:
• Lower bearing “1”
TIP
Remove the bearing by pressing its outer race.
EASB111179
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage Replace the rear shock
absorber assembly.
• Rear shock absorber
Gas leaks/oil leaks Replace the rear
shock absorber assembly.
•Spring
Damage/wear Replace.
• Spring guide
Damage/wear Replace.
• Bearing
Damage/wear Replace.
•Bolts
Bends/damage/wear Replace.
EASB111180CHECKING THE CONNECTING ARM AND
RELAY ARM
1. Check:
• Connecting arm
• Relay arm
Damage/wear Replace.
2. Check:
• Bearing
• Spacers
Damage/pitting/scratches Replace the
bearings and spacers as a set.
3. Check:
• Oil seals
Damage/pitting Replace.
EASB111181INSTALLING THE RELAY ARM
1. Lubricate:
• Oil seals
• Bearing
• Spacers
• Washers
•Collars
2. Install:
• Bearing “1”
• Washer “2”
• Oil seals “3”
(to relay arm “4”)
1
Recommended lubricant
Molybdenum disulfide grease
Installed depth “a”
0 mm (0 in)
New
Page 184 of 362
REAR SHOCK ABSORBER ASSEMBLY
4-60
3. Install:
• Bearing “1”
• Oil seals “2”
(to connecting arm “3”)
EASB111182INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY
1. Lubricate:
• Bearing (lower side)
•Dust seal
•Collars
• Bushing
ECA1DX1012
NOTICE
Do not apply the grease to the bearing outer
race because it will wear the rear shock ab-
sorber surface on which the bearing is
press fitted.
2. Lubricate:
• O-ring3. Install:
• Bearing
• Stopper ring
(to rear shock absorber assembly (upper
side))
TIP
• Install the bearing parallel until the stopper
ring groove appears by pressing its outer
race.
• After installing the stopper ring, push back the
bearing unit it contacts the stopper ring.
4. Install:
• Bearing “1”
• Bushing “2”
• Collar “3”
• Dust seal “4”
(to rear shock absorber assembly (lower
side))
TIP
Install the dust seals with their lips facing in-
ward.
5. Lubricate:
• Connecting arm and frame bolt
• Relay arm and connecting arm bolt
• Relay arm and swingarm bolt
(circumference and threaded portion)
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly lower bolt Installed depth “a”
0 mm (0 in)
Recommended lubricant
Molybdenum disulfide grease
Recommended lubricant
Molybdenum disulfide grease
3 3
43
2 2
22
a
1
11
New
3
a 1
12
a
2
Installed depth “a”
4.25 mm (0.17 in)
Recommended lubricant
Molybdenum disulfide grease
New
Page 186 of 362
SWINGARM
4-62
EASB111183
SWINGARM
Removing the swingarm
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Brake hose holder Refer to “REAR BRAKE” on page 4-22.
Rear brake caliper Refer to “REAR BRAKE” on page 4-22.
Bolt (brake pedal)
Drive chain
1Collars 2
2Oil seals 2
3Thrust bearing 2
4Bushing 2
5Oil seals 2
6Bearing 4
For installation, reverse the removal proce-
dure.
1
2
3
6
4
6
4
1
3
6
2
5
T.R.70 Nm (7.0 mlbf) kgf, 51 ft
T.R.4.0 Nm (0.40 mlbf) kgf, 2.9 ft
Page 187 of 362
SWINGARM
4-63
EASB111184REMOVING THE SWINGARM
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Measure:
• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the pivot
shaft nut.
b. Measure the swingarm side play “a” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EASB111185REMOVING THE BEARING
1. Remove:
• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EASB111186CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends Replace.
EWA
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check:
• Oil seals
Damage Replace.
• Bearing
• Spacers
Free play exists/unsmooth revolution/rust
Replace bearing and bushing as a set. Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial)
1.0 mm (0.04 in)
T R..
Page 188 of 362
SWINGARM
4-64
EASB111187INSTALLING THE SWINGARM
1. Lubricate:
• Bearing
•Collars
• Spacers
• Oil seal
• Pivot shaft
2. Install:
• Bearing “1”
• Oil seals “2”
(to the swingarm)
TIP
First install the outer and then the inner bear-
ings to a specified depth from inside.
3. Install:
• Swingarm
TIP
Install the pivot shaft from the right.
4. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-7.
5. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-28.Recommended lubricant
Molybdenum disulfide grease
Installed depth “a”
0–0.5 mm (0–0.02 in)
Installed depth “b”
6.5 mm (0.26 in)
Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Drive chain slack
50–60 mm (1.97–2.36 in)
New
New
2 22
1 1
aaa
b ba
NewNewNew
T R..
Page 194 of 362
CLUTCH......................................................................................................... 5-38
REMOVING THE CLUTCH ...................................................................... 5-41
CHECKING THE FRICTION PLATES...................................................... 5-41
CHECKING THE CLUTCH PLATES ........................................................ 5-41
CHECKING THE CLUTCH SPRINGS...................................................... 5-41
CHECKING THE CLUTCH HOUSING ..................................................... 5-42
CHECKING THE CLUTCH BOSS ............................................................ 5-42
CHECKING THE PRESSURE PLATE ..................................................... 5-42
CHECKING THE PUSH LEVER SHAFT .................................................. 5-42
CHECKING THE CLUTCH PUSH RODS ................................................ 5-42
CHECKING THE PRIMARY DRIVE GEAR .............................................. 5-42
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 5-43
INSTALLING THE OIL SEAL................................................................... 5-43
INSTALLING THE RIGHT CRANKCASE COVER ................................... 5-43
INSTALLING THE CLUTCH ..................................................................... 5-44
INSTALLING THE KICKSTARTER LEVER ............................................. 5-46
KICKSTATER................................................................................................. 5-47
REMOVING THE KICK SHAFT ASSEMBLY ........................................... 5-48
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 5-48
CHECKING THE KICK GEAR, KICK IDLE GEAR AND RATCHET
WHEEL .................................................................................................... 5-48
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 5-48
INSTALLING THE KICK IDLE GEAR ....................................................... 5-49
SHIFT SHAFT................................................................................................. 5-50
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 5-52
REMOVING THE SEGMENT ................................................................... 5-52
CHECKING THE SHIFT SHAFT .............................................................. 5-52
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 5-52
CHECKING THE STOPPER LEVER ....................................................... 5-52
INSTALLING THE STOPPER LEVER ..................................................... 5-53
INSTALLING THE SEGMENT.................................................................. 5-53
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 5-53
INSTALLING THE SHIFT SHAFT ............................................................ 5-54
INSTALLING THE SHIFT PEDAL ............................................................ 5-54
OIL PUMP AND BALANCER GEAR............................................................. 5-55
REMOVING THE BALANCER ................................................................. 5-57
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT
DRIVE GEAR, AND BALANCER WEIGHT GEAR .................................. 5-57
CHECKING THE BALANCER .................................................................. 5-57
CHECKING THE OIL PUMP .................................................................... 5-57
ASSEMBLING THE OIL PUMP ................................................................ 5-58
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 5-59
Page 195 of 362
AC MAGNETO................................................................................................ 5-61
REMOVING THE AC MAGNETO............................................................. 5-62
CHECKING THE AC MAGNETO ............................................................. 5-62
CHECKING THE WOODRUFF KEY ........................................................ 5-62
INSTALLING THE AC MAGNETO ........................................................... 5-62
CRANKCASE................................................................................................. 5-64
DISASSEMBLING THE CRANKCASE..................................................... 5-67
REMOVING THE CRANKCASE BEARING ............................................. 5-67
CHECKING THE TIMING CHAIN, TIMING CHAIN GUIDE, OIL
STRAINER .............................................................................................. 5-67
CHECKING THE CRANKCASE ............................................................... 5-68
ASSEMBLING THE CRANKCASE........................................................... 5-68
CRANKSHAFT ASSEMBLY AND BALANCER SHAFT............................... 5-69
REMOVING THE BALANCER SHAFT..................................................... 5-70
REMOVING THE CRANKSHAFT ASSEMBLY ........................................ 5-70
CHECKING THE CRANKSHAFT ASSEMBLY......................................... 5-70
INSTALLING THE CRANKSHAFT ASSEMBLY....................................... 5-71
TRANSMISSION............................................................................................. 5-72
REMOVING THE TRANSMISSION ......................................................... 5-73
CHECKING THE SHIFT FORKS.............................................................. 5-73
CHECKING THE SHIFT DRUM ASSEMBLY ........................................... 5-74
CHECKING THE TRANSMISSION .......................................................... 5-74
INSTALLING THE TRANSMISSION ........................................................ 5-74
Page 198 of 362
ENGINE REMOVAL
5-3
Removing the electronic parts
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case cover
1 Rectifier/regulator 1
2ECU 1
3 Ignition coil 1
4 Condenser 1
5 Neutral switch 1
6 AC magneto coupler 1 Disconnect.
7 Crankshaft position sensor coupler 1 Disconnect.
8 Coolant temperature sensor coupler 1 Disconnect.
For installation, reverse the removal proce-
dure.
T.R.
T.R.
T.R.T.R.
8 3
7
6
154
2
LT