Yamaha YZ450F 2007, YZ450FZ 2007 - Motorcycle Manual

GENERAL INFORMATION

LOCATION OF IMPORTANT LABELS

Please read the following important labels carefully before operating this vehicle.

CANADA

EUROPE

AUS, NZ, ZA

Familiarize yourself with the following pictograms and read the explanatory text.

	This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate, puncture or open.
	Turn off the main switch after riding to avoid draining the battery.
	Use unleaded gasoline only.
	Measure tire pressure when tires are cold.
	Adjust tire pressure. Improper tire pressure can cause loss of control. Loss of control can result in severe injury or death.

DESCRIPTION

1. Clutch lever
2. Front brake lever
3. Throttle grip
4. Radiator cap
5. Fuel tank cap
6. Engine stop switch
7. Kickstarter crank
8. Fuel tank
9. Radiator
10. Coolant drain bolt
11. Rear brake pedal
12. Valve joint
13. Air cleaner
14. Drive chain
15. Shift pedal
16. Oil level check window
17. Starter knob/idle screw
18. Front fork

TIP

• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.

CONSUMER INFORMATION

There are two significant reasons for knowing the serial number of your machine:

1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.
2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

VEHICLE IDENTIFICATION NUMBER
The vehicle identification number "1" is stamped on the right of the steering head pipe.

ENGINE SERIAL NUMBER
The engine serial number "1" is stamped into the elevated part of the right-side of the engine.

MODEL LABEL
The model label "1" is affixed to the frame under the rider's seat. This information will be needed to order spare parts.

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter thefuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine.
This model has adopted an electronically controlled fuel injection (FI) system, in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required bythe engine at all times by using a microprocessor that regulates the fuel injection volume according tothe engine operating conditions detected by various sensors.

1. Fuel injector
2. Throttle position sensor
3. Intake air pressure sensor
4. ECU
5. Fuel pump
6. Intake air temperature sensor
7. Atmospheric pressure sensor
8. Crankshaft position sensor
9. Coolant temperature sensor
10. Ignition coil
11. Condenser

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains thefuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm ², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causingthe fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, coolant temperature sensor, atmospheric pressure sensor, lean angle sensor, crankshaft position sensor, intake air pressure sensor and intake air temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions.

1. Fuel pump
2. Fuel injector
3. ECU
4. Throttle position sensor
5. Coolant temperature sensor
6. Crankshaft position sensor
7. Intake air pressure sensor
8. Throttle body
9. Intake air temperature sensor
10. Air filter case
11. Atmospheric pressure sensor
    1. Fuel system
    2. Intake system
    3. Control system

INCLUDED PARTS

DETACHABLE SIDESTAND
This sidestand "1" is used to support only the machine when standing or transporting it.

• Never apply additional force to the sidestand.
• Remove this sidestand before starting out.

VALVE JOINT
This valve joint "1" prevents fuel from flowing out and is installed to the fuel tank breather hose.

NOTICE
In this installation, make sure the arrow faces the fuel tank and also downward.

SPARK PLUG WRENCH
This spark plug wrench "1" is used to remove and install the spark plug.

NIPPLE WRENCH
This nipple wrench "1" is used to tighten the spoke.

HANDLEBAR PROTECTOR
Install the handlebar protector "1" so that the mark "a" face forward.

FUEL TANK HOLDING CABLE
The fuel tank holding cable "1" is used to support the fuel tank during maintenance.

FUEL HOSE JOINT COVER
The fuel hose joint covers "1" are used to prevent mud, dust, and other foreign material from entering the fuel pump when the fuel hose is disconnected.

COUPLER FOR CONNECTING OPTIONAL PART
This coupler "1" is used for connection to an optional Power Tuner and so on.

NOTICE
When no optional parts, etc. are connected, connect the connection terminal to the original coupler "2". Before removing the coupler, thoroughly wipe off any mud or water stuck to it.

Part name	Part number
YZ Power Tuner	33D-859C0-10

The YZ Power Tuner is optional.

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly.
   
   • When washing the machine with high pressured water, cover the parts follows.
     Air duct
     Silencer exhaust port
     Drain hole on the cylinder head (right side)
     Water pump housing hole at the bottom
     
2. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS" section.
   
3. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been "mated" through normal wear. Mated parts must be reused as an assembly or replaced.
   
4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.
   
5. Keep away from fire.

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/plates "1" and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.
   

BEARINGS AND OIL SEALS

1. Install the bearing(s) "1" and oil seal(s) "2" with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.
   

NOTICE
Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

CIRCLIPS

1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip "1", make sure that the sharp-edged corner "2" is positioned opposite to the thrust "3" it receives. See the sectional view.
   

HANDLING THE ELECTRONIC PARTS

NOTICE
Electronic parts are very sensitive. Handle with care and do not give impact.

• Mankind has static electricity. It's voltage is very high and electronic parts are very sensitive.
• It is possible that inner small components of electronic parts are destroyed by static electricity.
• Do not touch and do not make them dirty.
  

CHECKING OF CONNECTION

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

1. Disconnect:
   • Lead
   • Coupler
   • Connector
2. Check:
   • Lead
   • Coupler
   • Connector
     Moisture → Dry with an air blower.
     Rust/stains → Connect and disconnect several times.
     
3. Check:
   • All connections
     Loose connection → Connect properly.

TIP
If the pin "1" on the terminal is flattened, bend it up.

TIP
If the contact seems not good, pull the terminal by hand and check its condition.

4. Connect:
   • Lead
   • Coupler
   • Connector

TIP
Make sure all connections are tight.

5. Check:
   • Continuity
     (with the pocket tester)

Pocket tester:
90890-03112
Analog pocket tester:
YU-03112-C

TIP

• If there is no continuity, clean the terminals.
• When checking the wire harness, perform steps (1) to (5).
• As a quick remedy, use a contact revitalizer available at most part stores.

TIP
When you check the voltage or electrical continuity, insert the measuring probe from back side as you can insert from back side.

1. Probe
2. Coupler

REMOVING THE QUICK FASTENER

NOTICE
Do not push the center pin with too much force. Otherwise, the center pin could be damaged.

TIP
To remove a quick fastener, push the center pin in with a screwdriver, then pull the fastener out.

INSTALLING THE QUICK FASTENER

TIP
To install a quick fastener, push its center pin "a" back so that it protrudes from the fastener head, then insert the fastener and push the protruding pin in until it is flush with the fastener head.

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

TIP

• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
• For others, use part number starting with "90890-".

CONTROL FUNCTIONS

ENGINE STOP SWITCH
The engine stop switch "1" is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop.

CLUTCH LEVER
The clutch lever "1" is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

SHIFT PEDAL
The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal "1" on the left side of the engine.

KICKSTARTER CRANK
Rotate the kickstarter crank "1" away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

THROTTLE GRIP
The throttle grip "1" is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

FRONT BRAKE LEVER
The front brake lever "1" is located on the right handlebar. Pull it toward the handlebar to activate the front brake.

REAR BRAKE PEDAL
The rear brake pedal "1" is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

STARTER KNOB/IDLE SCREW
The starter knob/idle screw "1" is used when starting a cold engine. Pull the starter knob/idle screw out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.

STARTING AND BREAK-IN

FUEL
Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race.

Recommended fuel:
Premium unleaded gasoline only

NOTICE
Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.

TIP
Your Yamaha engine has been designed to use premium unleaded gasoline with a pump octane number [(R+M)/2] of 91 or higher, or a research octane number of 95 or higher. If knocking (or pinging) occurs, use a gasoline of a different brand.

• For refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire.
• Refuel after the engine, exhaust pipe, etc. have cooled off.

Gasohol (For USA and Canada)
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

HANDLING NOTE

Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area.

NOTICE

• Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kickstarter may kick back. Also, if the throttle is open the air/fuel mixture may be too lean for the engine to start.
• Before starting the machine, perform the checks in the pre-operation check list.

AIR FILTER MAINTENANCE

Apply the foam-air-filter oil or its equivalent to the element. (Excess oil in the element may adversely affect engine starting.)

STARTING A COLD ENGINE

1. Inspect the coolant level.
2. Shift the transmission into neutral.
3. Pull the starter knob/idle screw "1" to its full length.
   

TIP
Use the starter knob/idle screw below an air temperature of 15°C (59°F).

4. Push the kickstarter down lightly with your foot until resistance is felt.
5. With the throttle fully closed, fold out the kickstarter lever, move it down lightly with your foot until the gears engage, and then push it down smoothly but forcefully.

Do not open the throttle while kicking the kickstarter crank. Otherwise, the kickstarter crank may kick back.

TIP
If the engine fails to start, give the kickstarter 10 to 20 slow kicks at full throttle in order to clear the engine of the rich air-fuel mixture retained in it.

6. When the engine starts running, warm it up one or two minutes at a steady speed (of 3,000 to 5,000 r/min), and then return the starter knob/ idle screw to its original position.
7. Push the engine stop switch "1".
   

NOTICE
Do not warm up the engine for extended periods of time.

STARTING A WARM ENGINE

To start a warm engine, make sure that the starter (choke) knob/idling screw is pushed in and the throttle is closed, and then start the engine by pushing the kickstarter.

TIP
If the engine fails to start, give the kickstarter 10 to 20 slow kicks at full throttle in order to clear the engine of the rich air-fuel mixture retained in it.

BREAK-IN PROCEDURES

1. Before starting the engine, fill the fuel tank with the fuel.
2. Perform the pre-operation checks on the machine.
3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted.
4. Operate the machine in the lower gears at moderate throttle openings for five to eight minutes.
5. Check how the engine runs when the machine is ridden with the throttle 1/4 to 1/2 open (low to medium speed) for about one hour.
6. Restart the engine and check the operation of the machine throughout its entire operating range. Restart the machine and operate it for about 10 to 15 more minutes. The machine will now be ready to race.

NOTICE

• After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per "TORQUE- CHECK POINTS". Tighten all such fasteners as required.
• When any of the following parts have been replaced, they must be broken in.
  CYLINDER AND CRANKSHAFT:
  About one hour of break-in operation is necessary.
  PISTON, RING, VALVES, CAM- SHAFTS AND GEARS:
  These parts require about 30 minutes of break-in operation at half-throttle or less. Observe the condition of the engine carefully during operation.

TORQUE-CHECK POINTS

TIP
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section.

CLEANING AND STORAGE

CLEANING

Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components.

1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.
3. Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do the job.

NOTICE
Do not use high-pressure washers or steam-jet cleaners since they cause water seepage and deterioration seals.

4. After the majority of the dirt has been hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places.
5. Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth.
6. Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
8. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleanerwaxes, as they may contain abrasives.
9. After completing the above, start the engine and allow it to idle for several minutes.

STORAGE

If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows:

1. Fill up the fuel tank and add fuel stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating.
2. Remove the spark plug, pour a tablespoon of SAE 10W-40 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil.
3. Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off the ground.
6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering.
7. If the machine is to be stored in a humid or salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover.

TIP
Make any necessary repairs before the machine is stored.

SPECIFICATIONS

GENERAL SPECIFICATIONS

NOTICE

Model name:		YZ450FZ (USA, CDN, AUS, NZ) YZ450F (EUROPE, ZA)
Model code number:		33D1 (USA,CDN) 33D2 (EUROPE) 33D4 (AUS, NZ, ZA)
Dimensions:		USA, CDN	EUROPE	AUS, NZ, ZA
Overall length		2,193 mm (86.34 in)	2,191 mm (86.26 in)	2,194 mm (86.38 in)
Overall width		825 mm (32.48 in)	←	←
Overall height		1,311 mm (51.61 in)	←	←
Seat height		999 mm (39.33 in)	←	998 mm (39.29 in)
Wheelbase		1,492 mm (58.74 in)	1,487 mm (58.54 in)	←
Minimum ground clearance		383 mm (15.08 in)	←	384 mm (15.12 in)
Weight: With oil and fuel		USA, CDN	EUROPE	AUS, NZ, ZA
		111.3 kg (245 lb)	111.9 kg (247 lb)	111.5 kg (246 lb)
Engine:
Engine type		Liquid cooled 4-stroke, DOHC
Cylinder arrangement		Single cylinder, Backward inclined
Displacement		449.7 cm3 (15.8 Imp oz, 15.2 US oz)
Bore × stroke		97.0 × 60.8 mm (3.82 × 2.39 in)
Compression ratio		12.5:1
Starting system		Kickstarter
Lubrication system:		Dry sump
Oil type or grade: Engine oil		Recommended brand: YAMALUBE SAE10W-30, SAE10W-40, SAE10W-50, SAE15W-40, SAE20W-40 or SAE20W-50 API service SG type or higher, JASO standard MA
Oil capacity: Engine oil
Periodic oil change		0.95 L (0.84 Imp qt, 1.00 US qt)
With oil filter replacement		1.0 L (0.88 Imp qt, 1.06 US qt)
Total amount		1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes):		1.13 L (0.99 Imp qt, 1.19 US qt)
Air filter:		Wet type element
Fuel:
Type		Premium unleaded gasoline only
Tank capacity		6.0 L (1.30 Imp gal, 1.59 US gal)
Throttle body:
Type		30RA
Manufacturer		KEIHIN
Spark plug:
Type/manufacturer		CR8E/NGK (resistance type)
Gap		0.7–0.8 mm (0.028–0.031 in)
Clutch type:		Wet, multiple-disc
Transmission:
Primary reduction system		Gear
Primary reduction ratio		61/23 (2.652)
Secondary reduction system		Chain drive
Secondary reduction ratio		48/13 (3.692) (For USA, CDN) 49/13 (3.769) (For EUROPE, AUS, NZ, ZA)
Transmission type		Constant mesh, 5-speed
Operation		Left foot operation
Gear ratio:	1st	27/14 (1.929)
	2nd	23/15 (1.533)
	3rd	23/18 (1.278)
	4th	24/22 (1.091)
	5th	20/21 (0.952)
Chassis:		USA, CDN	EUROPE	AUS, NZ, ZA
Frame type		Bilateral beam	←	←
Caster angle		26.9°	26.8°	26.9°
Trail		118.6 mm (4.67 in)	117.5 mm (4.63 in)	119.0 mm (4.69 in)
Tire:
Type		With tube
Size (front)		80/100-21 51M
Size (rear)		120/80-19 63M (For USA, CDN, AUS, NZ, ZA) 110/90-19 62M (For EUROPE)
Tire pressure (front and rear)		100 kPa (1.0 kgf/cm2, 15 psi)
Brake:
Front brake type		Single disc brake
Operation		Right hand operation
Rear brake type		Single disc brake
Operation		Right foot operation
Suspension:
Front suspension		Telescopic fork
Rear suspension		Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber		Coil spring/oil damper
Rear shock absorber		Coil spring/gas, oil damper
Wheel travel:
Front wheel travel		310 mm (12.2 in)
Rear wheel travel		315 mm (12.4 in) (For USA, CDN) 312 mm (12.3 in) (For EUROPE, AUS, NZ, ZA)
Electrical: Ignition system		TCI

MAINTENANCE SPECIFICATIONS

ENGINE

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