2016 YAMAHA YZ450F checking oil

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

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
3-16
d. Install the oil strainer.
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6. Install:
• Engine oil drain bolt
• Drain bolt
7. Pour the specified amount of engine oil into
the oil filler cap hole.
8. Install:
• Oil filler cap
9. Check:
• Oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-14.
10.Check:
• Engine oil pressure
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a. Slightly loosen the oil pressure check bolt
“1”.
EWA
WARNING
When the engine is started with the check
bolt removed, oil will spout; therefore, al-
ways loosen it before the checkup.
Start the engine and keep it idling until oil
starts to seep from the oil pressure check
bolt.
EWA
WARNING
Always keep the engine idling speed during
the checkup without increasing the engine
speed.
ECA
NOTICE
If no engine oil seeps out after one minute,
immediately turn the engine off so it will not
seize.
b. If no engine oil seeps out, check the engine
oil for leaks, and the engine oil passage and
the oil pump for damage.
c. Check the oil pressure again.
d. Tighten the oil pressure check bolt.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲EASB111086ADJUSTING THE ENGINE IDLING SPEED
TIP
• Because the air pressure is lower at high alti-
tudes, the air-fuel mixture will become richer.
If the idling speed is low, turn the starter knob/
idle screw a few clicks counterclockwise to in-
crease the speed before the adjustment.
• Before adjusting the engine idling speed,
make sure that the air filter element is not
clogged, the engine compression is proper,
and the throttle grip free play is proper.
• Adjust the engine idling speed with the starter
knob/idle screw pushed in completely. Oil strainer bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drain bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)
Engine oil quantity
With oil filter element replace-
ment
0.69 L (0.73 US qt, 0.61 Imp.qt)
Quantity (disassembled)
0.95 L (1.00 US qt, 0.84 Imp.qt)
1
2New
T R..
New
T R..
Oil pressure check bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
1
T R..

CHASSIS
3-29
TIP
• To maintain the proper wheel alignment, ad-
just both sides evenly.
• Push the rear wheel forward to make sure that
there is no clearance between the swingarm
end plates and the ends of the swingarm.
d. Tighten the locknut.
e. Tighten the wheel axle nut.
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EASB111098CHECKING THE FRONT FORK LEGS
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Inner tube
Damage/scratches  Replace.
• Front fork leg (s)
Oil leaks between inner tube and outer tube
 Replace the oil seal.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Unsmooth operation  Correct or replace.
Refer to “FRONT FORK” on page 4-38.
EASB111099CHECKING THE FRONT FORK PROTEC-
TOR GUIDE
1. Check:
• Protector guide “1”
Out of specification  Replace.
TIP
The protector guide reaches the limit of its use
when it is worn down to the same height “a” as
of the outer tube circumference.
EASB111100CLEANING THE FRONT FORK OIL SEAL
AND DUST SEAL
1. Remove:
•Protector
• Dust seal “1”
ECA
NOTICE
Be careful not to damage the dust seal and
the inner tube by a driver. Locknut
21 Nm (2.1 m·kgf, 15 ft·lbf)
Wheel axle nut
135 Nm (13.5 m·kgf, 98 ft·lbf)
1
32
a
b
T R..
T R..1
a
1

CHASSIS
3-31
Compression dampingECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Adjust:
• Compression damping
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a. Turn the adjuster “1” in the direction of “a” or
“b” to make an adjustment.
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EASB111103CHECKING THE SWINGARM OPERATION
1. Check:
• Swingarm smooth action
• Swingarm free play
Refer to “SWINGARM” on page 4-62.
EASB111104
CHECKING THE REAR SUSPENSION
1. Stand the vehicle upright on a level surface.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Check:
• Rear shock absorber assembly
Gas leaks/oil leaks  Replace the rear
shock absorber assembly.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-55.
3. Check:
• Rear shock absorber assembly smooth ac-
tion
• Rear suspension link smooth action
Sit astride the seat and shake your body up
and down several times to check whether
the rear shock absorber assembly operates
smoothly.
Unsmooth operation  Correct or replace.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-55.
EASB111105ADJUSTING THE REAR SHOCK ABSORB-
ER ASSEMBLY
Use a suitable stand to raise the rear wheel off
the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
Spring preload
ECA@
NOTICE
Do not turn the adjuster forcibly beyond its
adjusting range.
1. Remove:
• Rear frame
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-55. Direction “a”
Compression damping is increased
(suspension is harder).
Direction “b”
Compression damping is decreased
(suspension is softer).
Compression damping adjusting
positions
Maximum
Fully turned in
Standard
8 clicks out* (USA) (CAN)
16 clicks out* (EUR) (JPN) (AUS)
(NZL) (ZAF)
Minimum
20 clicks out*
* With the adjuster fully turned in
a b
1

FRONT WHEEL
4-4
EASB111122REMOVING THE FRONT WHEEL
1. Use a suitable stand to raise the front wheel
off the ground.
EWA
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Front wheel
EASB111123CHECKING THE FRONT WHEEL
1. Check:
• Front wheel axle
Roll the front wheel axle on a flat surface.
Bends  Replace.
EWA
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
•Tire(s)
• Front wheel
Damage/wear  Replace.
Refer to “CHECKING THE TIRES” on page
3-34 and “CHECKING THE WHEELS” on
page 3-34.
3. Check:
• Spokes
Bend/damage  Replace.
Loose  Tighten.
Tap the spokes with a screwdriver.
TIP
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
4. Tighten:
• Spokes
Refer to “CHECKING AND TIGHTENING
THE SPOKES” on page 3-34.
TIP
After tightening the spokes, measure the wheel
runout.
5. Measure:
• Wheel radial runout “a”
• Wheel lateral runout “b”
Out of specification  Repair/replace.
6. Check:
•Collars
Damage/wear  Replace.
7. Check:
• Bearing
Front wheel turns roughly or is loose  Re-
place the wheel bearings.
• Oil seals
Damage/wear  Replace.
Spokes
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
T R..
ab

REAR WHEEL
4-8
EASB111128REMOVING THE REAR WHEEL
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. Remove:
• Rear wheel axle nut “1”
3. Loosen:
• Locknut “2”
4. Tighten:
• Adjusting bolt “3”
5. Remove:
• Rear wheel axle
• Rear wheel
TIP
• Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
• Do not depress the brake pedal with the rear
wheel removed.
EASB111129CHECKING THE REAR WHEEL
1. Check:
• Rear wheel axle
• Rear wheel
• Bearing
• Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.
2. Check:
•Tire(s)
• Rear wheel
Damage/wear  Replace.
Refer to “CHECKING THE TIRES” on page
3-34 and “CHECKING THE WHEELS” on
page 3-34.
3. Check:
• Spokes
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.4. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-4.
EASB111130DISASSEMBLING THE REAR WHEEL
1. Remove:
• Oil seals
• Bearing
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-5.
EASB111131CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth wear “a”  Replace the
rear wheel sprocket and the drive sprocket
as a set.
Bent tooth  Replace the rear wheel
sprocket and the drive sprocket as a set.
2. Replace:
• Rear wheel sprocket
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a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
3
12
Radial wheel runout limit
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
b. Correct
1. Drive chain roller
2. Rear wheel sprocket
Rear wheel sprocket self-locking
nut
42 Nm (4.2 m·kgf, 30 ft·lbf)
T R..