2016 YAMAHA YZ450F radiator

DESCRIPTION
1-4
EASB111009
DESCRIPTION
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have pur-
chased.1. Clutch lever 10. Radiator
2. Front brake lever 11. Coolant drain bolt
3. Throttle grip 12. Rear brake pedal
4. Radiator cap 13. Air filter
5. Fuel tank cap 14. Drive chain
6. Launch control switch 15. Shift pedal
7. Engine stop switch 16. Oil level check window
8. Fuel tank 17. Starter knob/idle screw
9. Kickstarter lever 18. Front fork
2 1
7
6
89 1054 3
12 11 18 17 16 15 1413

SPECIAL TOOLS
1-14
Radiator cap tester
90890-01325
Mityvac cooling system tester
kit
YU-24460-AThis tool is used to check the
radiator and the radiator cap.
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984This tool is used to check the
radiator and the radiator cap.
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472This tool is used to remove or
tighten the steering nut.
Cap bolt wrench
90890-01500
YM-01500This tool is used to remove or
tighten the base valve.
Cap bolt ring wrench
90890-01501
YM-01501This tool is used to loosen or
tighten the damper assem-
bly.
Fork seal driver
90890-01502
YM-A0948This tool is used to install the
oil seal of the front fork.
Spoke nipple wrench (6–7)
90890-01521
YM-01521This tool is used to tighten the
spoke. Tool name/Part number How to use Illustration

ENGINE SPECIFICATIONS
2-2
EASB111052
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 450 cm
3
Cylinder arrangement Single cylinder
Bore  stroke 97.0  60.8 mm (3.8  2.4 in)
Compression ratio 12.5:1
Starting system Kickstarter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 7.5 L (1.98 US gal, 1.65 Imp.gal)
Engine oil
Lubrication system Wet sump
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
Engine oil quantity
Quantity (disassembled) 0.95 L (1.00 US qt, 0.84 Imp.qt)
With oil filter element replacement 0.69 L (0.73 US qt, 0.61 Imp.qt)
Without oil filter element replacement 0.67 L (0.71 US qt, 0.59 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Oil pump type Trochoid
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)
Cooling system
Radiator (including all routes) 1.04 L (1.10 US qt, 0.92 Imp.qt)
Radiator capacity 0.57 L (0.60 US qt, 0.50 mp.qt)
Radiator cap valve opening pressure 108–137 kPa (1.08–1.37 kg/cm
2, 15.7–19.9
psi)
Radiator core
Width 112.6 mm (4.43 in)
Height 235.0 mm (9.25 in)
Depth 28.0 mm (1.10 in)
Water pump
Water pump type Single suction centrifugal pump
Spark plug(s)
Manufacturer/model NGK/CR8E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)

TIGHTENING TORQUES
2-13
EASB111056ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks
Camshaft cap bolt
M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug
M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plug
M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt (exhaust
pipe)M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head bolts
M9 4 See TIP.
*1
Cylinder head bolts
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover bolt
M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage plug (cylinder head)
M8 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw
M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf)Use a
lock
washer.
Balancer nut M10 1 45 Nm (4.5 m·kgf, 33 ft·lbf)Use a
lock
washer.
Timing chain guide stopper plate
(exhaust side)M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt
M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw
M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump housing cover bolt
M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt
M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screw
M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage cover bolt (left crank-
case)M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt
M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint clamp bolt
M5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
E
LT
M
LT
LT
LT

TIGHTENING TORQUES
2-19
TIP
1. First, tighten the lower ring nut approximately 38 Nm (3.8 m·kgf, 27 ft·lbf) by using the steering nut
wrench, then loosen the lower ring nut one turn.
2. Retighten the lower ring nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf).Drive chain tensioner bolt (lower
side)M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Drive chain support bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain support nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive chain guide bolt M5 3 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear frame and left cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (front side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt (rear side) M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Fuel tank bracket bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bracket bolt (rear side) M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump bolt M5 6 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Fuel inlet pipe screw M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Fuel tank cap cover bolt M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Seat set bracket and fuel tank screw M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat bolt M8 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Left side cover bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Right side cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Frame and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank and air scoop bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Radiator guard and air scoop bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear fender bolt (front side) M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt (rear side) M6 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Mud flap screw — 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Number plate bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)ITEMThread
sizeQ’ty TIGHTENING TORQUES Remarks

CABLE ROUTING DIAGRAM
2-32
1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Launch control switch lead
5. Engine stop switch lead
6. Cable holder
7. Coupler for connecting optional part
8. Engine stop switch coupler
9. Launch control switch coupler
10. Rectifier/regulator coupler
11. AC magneto lead
12. Starter knob/idle screw
13. Neutral switch lead
14. Crankcase cover
15. Front engine bracket
16. Radiator hose
17. Neutral switch coupler
18. AC magneto coupler
19. Tension arm
20. Rectifier/regulator lead
21. Main harness
22. Tank rail
23. Radiator
24. Cylinder head breather hose
25. Radiator breather hose
26. Down tube
27. Crankcase
A. Pass the engine stop switch lead and the launch
control switch lead between the frame and the ca-
ble holder. Route the launch control switch lead
above the engine stop switch lead.
B. Insert the coupler for connecting optional part into
the connector, and fix it to the bracket.
C. Insert and fix the engine stop switch coupler to
the bracket.
D. Make sure that the launch control switch lead
does not contact the radiator.
E. Insert and fix the launch control switch coupler to
the bracket.
F. Insert and fix the rectifier/regulator coupler to the
bracket.
G. Pass the AC magneto lead to the front of the ve-
hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
H. 70 mm (2.76 in)
I. Bring the neutral switch lead into line with the
crankcase cover with no sag allowed.
J. Bring the AC magneto lead into line with the
clutch cable with no sag allowed.
K. Pass the neutral switch lead to the inside of the
front engine bracket (the side of the vehicle).
L. Clamp the clutch cable and the AC magneto lead
by the plastic locking tie. Regardless of the orien-
tation of the lock on the plastic locking tie, cut the
end.
M. Pass the clutch cable with no downward sag al-
lowed.
N. Bring the grommet of the clutch cable into contact
with the radiator hose, and pass it to the outside
of the neutral switch lead and the AC magneto
lead (the outside of the vehicle).
O. 40 mm (1.57 in)
P. Clamp the clutch cable, the AC magneto lead,
and the neutral switch lead by the plastic locking
tie. Make sure that they are clamped at the posi-
tioning tape in the clutch cable. Make the lock on
the plastic locking tie face the front of the vehicle,
and cut the end.Q. After connecting the neutral switch coupler, at-
tach the coupler cover.
R. After connecting the AC magneto coupler, attach
the coupler cover.
S. Pass the rectifier/regulator lead to the inside of
the tension arm (the side of the vehicle).
T. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside of
the throttle cable (the side of the vehicle).
U. Pass the engine stop switch lead and launch con-
trol switch lead between the coupler for connect-
ing optional part and the tank rail.
V. Pass the radiator breather hose between the
down tubes.
W. Clamp the radiator breather hose, above the en-
gine bracket (front). Clamp the lock on the plastic
tie with it located outside the vehicle, and face the
end toward the front of the vehicle.
X. Clamp the clutch cable at the front of the lead (the
front of the vehicle).
Y. Make the lock on the plastic locking tie face the
front of the vehicle, and insert the projection into
the hole in the frame. Cut the end of the plastic
locking tie.

CABLE ROUTING DIAGRAM
2-34
1. Bracket
2. Condenser
3. Coolant temperature sensor
4. Coupler cover
5. Intake air pressure sensor coupler
6. Intake air temperature sensor coupler
7. Radiator hose
8. Radiator breather hose
9. Joint coupler
10. Plate
11. Tension arm
12. Throttle position sensor lead
13. Ground lead
14. Throttle position sensor coupler
15. Radiator breather hose
16. Cylinder head breather hose
17. Engine guard
18. Crankcase
19. Fuel pump coupler
20. Fuel hose
21. Condenser lead
22. Fuel pump lead
23. Condenser coupler
24. Ground lead terminal
25. Fuel tank
26. Damper
27. Rear frame
28. Main harness
A. Insert the condenser into the bracket as far as it
will go.
B. Attach the coupler cover to the coolant tempera-
ture sensor coupler.
C. Pass the radiator breather hose to the inside of
the radiator hose (the side of the vehicle).
D. Insert and fix the joint coupler to the plate. After
fixing it, attach the cover.
E. Pass the throttle position sensor lead to the out-
side of the tension arm (the outside of the vehi-
cle).
F. After connecting the throttle position sensor cou-
pler, attach the cover.
G. Pass the radiator breather hose to the outside of
the tension arm and the throttle position sensor
lead (the outside of the vehicle), and to the inside
of the radiator hose (the side of the vehicle).
H. Pass the protector of the cylinder head breather
hose until it touches the holder.
I. Pass the cylinder head breather hose between
the engine guard and the crankcase.
J. Install the end of the cylinder head breather hose
with it facing downward.
K. After connecting the fuel pump coupler, attach
the coupler cover.
L. 55 mm (2.17 in) (seat load receiver)
M. Clamp the fuel hose and the fuel pump lead by
the holder. Make sure that the painted part on the
fuel hose is clamped, and face the lock on the
clamp toward the rear top of the vehicle.
N. Do not install the plastic locking tie to the seat
load receiver.
O. Make the lock on the plastic locking tie face the
front of the vehicle, and make the end face the
bottom of the vehicle. Do not cut the end.
P. Install the ground lead terminal between the plate
and the bolt.
Q. Detent
R. Fix the ground lead terminal to the detent in the
plate. For the ground lead terminal, either side
will do.S. Insert the projection on the plastic locking tie into
the hole in the rear frame.
T. Clamp the painted part on the fuel hose by the
plastic clamp. Make the lock on the plastic clamp
face the bottom of the vehicle, and cut the end.

CABLE ROUTING DIAGRAM
2-38
1. Main harness
2. Radiator
3. Throttle position sensor lead
4. Joint coupler
5. Intake air temperature sensor lead
6. Intake air pressure sensor lead
7. Frame
8. Fuel hose
9. High tension cord
10. Spark plug cap
11. Cylinder head cover
12. Sub-wire harness
13. Sub-wire harness coupler
14. Injector coupler
15. Injector lead
16. Launch control switch coupler
17. Launch control switch lead
18. Launch control switch lead (main harness side)
19. Rectifier/regulator lead (main harness side)
20. Grommet (high tension cord)
21. Air filter case
22. ECU
A. Fix the main harness by the plastic clamp, and in-
sert the projection of the plastic clamp into the
hole in the sheet metal of the radiator.
B. Insert the projection of the main harness into the
hole in the frame.
C. To the sub-wire harness
D. Pass the high tension cord above the fuel hose.
E. ±10°
F. Install the spark plug cap with this facing the right
of the vehicle.
G. Push the spark plug cap home, where there shall
be no gap between it and the cylinder head cover.
H. Pass the injector lead to the top of the vehicle be-
yond the fuel hose.
I. Apply adhesive to the slit and inside of the grom-
met, and then fix the grommet according to the
specified dimensions.
J. 50±3 mm (2.0±0.12 in)
K. Insert the coupler of the sub-wire harness into the
rib of the air filter case.
L. Pass the sub-wire harness between the ECU and
the air filter case.