2011-2012 Yamaha YZ450F Service & Repair Manual

2012 OWNER’S SERVICE MANUAL YZ450FB 33D-28199-12 LIT-11626-25-11 q Read this manual carefully before operating this vehicle.

Q Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

YZ450FB OWNER'S SERVICE MANUAL ©2011 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2011 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-25-11

INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Ya- maha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, ba- sic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If you have any questions concerning this manual, please con- sult your Yamaha dealer. PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OP- ERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWL- EDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILI- TIES AND THE RELIABILITY OF THIS MA- CHINE. IMPORTANT MANUAL INFORMATION Particularly important information is distin- guished in this manual by the following nota- tions. This is the safety alert symbol. It is used to alert you to potential personal injury haz- ards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situa- tion which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedures easier or clearer.

SAFETY INFORMATION THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. • THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics. • THIS MACHINE IS DESIGNED TO BE RID- DEN BY THE OPERATOR ONLY. Do not carry passengers on this machine. • ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine. • ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre- operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident. • GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vi- cinity of an open flame, or while smoking. • GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. • ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a danger- ous gas which can cause unconsciousness or can be lethal. • PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over. • THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair. • PROPERLY SECURE THE MACHINE BE- FORE TRANSPORTING IT. For safety, drain the gasoline from the fuel tank before transporting the vehicle.

YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants to the original retail purchaser that the following components equipped on new Yamaha YZ motorcycles purchased from an authorized Yamaha motorcycle dealer in the continental Untted States will be free from defects in materiel and workmanship for the period of time stated herein, subject to certain stated limitations. YZ components included under this warranty are the engine, frame, swingarm, and monoshock. It is understood that the balance of the YZ components are not covered by any warranty, expressed or implied. The balance of the components equipped on the unit are sold on an "as is 11 basis. This warranty applies to the original purchaser only and is not transferable. THE PERIOD OF WARRANTY for the above-listed Yamaha YZ components as originally installed on the unit shall be thirty (30) days from the date ol purchase. MODELS EXCLUDED FROM WARRANTY include those used for non-Yamaha-authorized renting, leasing, or other commercial purposes. DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will, free of charge, repair or replace, at Yamaha's option, any part adjudged defective by Yamaha due to faulty workmanship or material from the factory. Parts used In warranty repairs will be warranted for the balance of the product 1 s warranty period. All parts replaced under warranty become pr operty of Yamaha Motor Corporation, U.S.A. GENERAL EXCLUSIONS from this warranty shall include any failures caused by: a. Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts. b. Abnormal strain, neglect, or abuse. c. Accident or collision damage. d. Modification to original parts. e. Lack of proper maintenance. f . Damage due to improper transportation. SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance. THE CUSTOMER'S RESPONSIBILITY under this warranty shall be to: 1. Operate and maintain the YZ as specified in the appropriate Owner 1 s Service Manual, and 2. Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten (1 0) days alter discovery, and make the machine available at that time for inspection and repairs at such dealer's place of business. YAMAHA MOTOR CORPORATION, U.S.A. MAKES NO OTHER WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED. ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION, U.S.A. AND EXCLUDED FROM THIS WARRANTY. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. ALSO EXCLUDED FROM THIS WARRANTY ARE WARRANTY QUESTIONS AND ANSWERS ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. YAMAHA MOTOR CORPORATION, U.S.A. CUSTOMER SERVICE Post Office Box 6555 Cypress, California 90630 Q. What costs are my responsibility during the warr anty period? A. The customer' s r esponsibility inc ludes all costs of no rmal maintenance services, non-warranty r epairs, accident and colli sion dam age, and oil, o il filters, air filters, spark plugs, and brake shoes or pads. Q. What are some examples of "abnormal '" strain. negl ect, or abuse? A. These te,-ms are general and overlap each other in areas. Specific exampl es include: Run- ni ng the m achine w itho ut oil; operating the machi ne w it h a b r oken or damaged part which causes another part t o fail , dam age or failure due to i mproper o r. careless tra nspor- t ation and or tie down; and so on. If you have any specific questions on operati on or mai ntenance, please contact your deale,- for adv ice. If yo ur machine requires w arranty serv ice, you must take it to any authorized Yamaha m otorcycle dealer wit hin the conti nental United States. Be sure to bring yo ur w art"anty regist ration i dentification or other valid proof of the o rigi nal date of purchase. If a q uestion or problem arises regardi ng w ar ranty, first cont act the owner of the deal er-shi p. Since all w arranty matters are handled at the dealer level. t his person is in the best position to help you. If you are still not satisfied and require additional assist ance, please write: 0. Does the warr anty cover incidental costs such as tow ing or transportat ion due to a fai l- ure? A. No. The w arranty is limited to repair of the m achi ne itself. Q. May I perform any or all of the recommended maintenance shown in the Owner' s Service Manual instead of having the dealer do them? A. Yes, if you are a qualifi ed mechanic and fo ll ow the proced ures specified in the Owner's Service M an ual. We do recommend, how ever, that items r equi ri ng special t ools or equip- ment be do ne by a Yamaha moto rcycle dealer. 0. Will the w arra nty be vo id or cancel ed if I do not operate or maintain my new YZ exact· ly as specified in the Owner's Service Manual? A. No. The warranty on a new motorcycle cannot be "vo ided" or "cancelled." However, if a particular failure is caused by operation or maintenance other than as shown in the Owne,- 's SMvice Manual, that failure may not be covered under warranty. 0. What r esponsibility does my dealer have u nder this w ar ranty? A. Each Yama ha motorcycle dealer is expected t o: 1. Complete ly set up every new m achine bef ore sale. 2. Explain the operat ion, maint enance, and warranty r eq uirements to you r sati sf acti on at the time of sale, and upon your request at any later date. In additio n, each Yamaha motorcycle dealer is held responsible f or hi s setup. service and w arranty repair work. 0. Does the w arr anty on the engine include t he carb uret or. air f ilte r, air box, and exhaust pipe? A. No. The war-ranty covers on ly the engine co mponents. YAMAHA MOTOR CORPORATION U.S.A. CUSTOMER RELATIONS DEPARTMENT P.O. Box 6 555 Cypress, Cal ifornia 90630 When contact ing Ya m aha Motor Corporat ion, U.S.A. don't forget to inclu de any i mpo rtant infor mati on such as nam es. addresses, model, V. I.N. (frame nu mber), dates. and recei pts. CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to mai n- tain a complete, up-to· date l ist of all fi rst purchasers against the possibil ity of a saf ety-relat ed defect and r eca ll. This list is compiled from the pu rchase regi stra- tions sent to Yamaha M otor Co rporation, U.S.A. by the selli ng dealer at the ti me of your purchase. If y ou should move after you have purchased yo ur new motorcycle, please advise us of your new address by sending a post card listing your motorcycle model nam e, V.I.N. (frame number ). dealer number (or deale's name) as it is shown on your war ranty identificati on, your name and new m ailing addr ess. Mail to: YAMAHA MOTOR CORPORATION, U.S.A. WARRANTY DEPARTMENT P.O .Box 6555 Cypress, Califor nia 90630 This will ensure that Yamaha Motor Corporation, U.S.A. has an up-to-date r egis- t ration r ecord in accordance wi th federal law .

HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of eight chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis", "Fuel system", "Electrical" and "Tuning". 2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description. MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/damage → Replace.

HOW TO READ DESCRIPTIONS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks "3". The meanings of the symbol marks are given on the next page. 4. A job instruction chart "4" accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements "5" are given in addition to the exploded diagram and job instruction chart.

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols "1" to "7" are used to identify the specifications appearing in the text. 1. With engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening 6. Specified value, Service limit 7. Resistance (Ω), Voltage (V), Electric current (A) Illustrated symbols "8" to "13" in the exploded diagrams indicate grade of lubricant and loca- tion of lubrication point. 8. Apply engine oil 9. Apply molybdenum disulfide oil 10. Apply brake fluid 11. Apply lightweight lithium-soap base grease 12. Apply molybdenum disulfide grease 13. Apply silicone grease Illustrated symbols "14" to "15" in the exploded diagrams indicate where to apply a locking agent and where to install new parts. 14. Apply locking agent (LOCTITE ® ) 15. Use new one

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2011-2012 Yamaha YZ450F Service & Repair Manual

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