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

EAS1SL1002

YZ450FE

OWNER’S SERVICE MANUAL

©2013 by Yamaha Motor Corporation, U.S.A.

1st Edition, April 2013

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-11626-27-21

EAS1SL1003

INTRODUCTION

Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha'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, basic maintenance and tuning of your machine. If you

have any questions about this manual or your machine, please contact your Yamaha dealer.

TIP

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 consult your Yamaha dealer.

EWA1DX0001

WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS

MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A

SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL

YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPEC-

TIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE

THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

EAS1SL1004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.

This is the safety alert symbol. It is used to alert you to potential personal

injury hazards. Obey all safety messages that follow this symbol to avoid

possible injury or death.

A WARNING indicates a hazardous situation 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.

WARNING

NOTICE

TIP

EAS1SL1005

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 char-

acteristics.

• THIS MACHINE IS DESIGNED TO BE RIDDEN 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-oper-

ation 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 ex-

haust system. Never refuel in the vicinity 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, imme-

diately 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. Car-

bon monoxide is a dangerous 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 EN-

GINE 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 BEFORE TRANSPORTING IT.

For safety, drain the gasoline from the fuel tank before transporting the vehicle.

EAS1SL1006

YAMAHA MOTOR CORPORATION, U.S.A.

YZ MOTORCYCLE LIMITED WARRANTY

EAS1SL1007

HOW TO USE THIS MANUAL

In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment

procedures are laid out with the individual steps in sequential order.

• The manual is divided into chapters and each chapter is divided into sections. The current section

title “1” is shown at the top of each page.

• Sub-section titles “2” appear in smaller print than the section title.

• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of

each removal and disassembly section.

• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a re-

moval or a disassembly step.

• Symbols “5” indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, the

names of parts, the notes in jobs, etc.

• Jobs “7” requiring more information (such as special tools and technical data) are described se-

quentially.

1

7

3

4

6

2

5

EAS1SL1008

SYMBOLS

The following symbols are used in this manual for easier understanding.

TIP

The following symbols are not relevant to every vehicle.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Serviceable with engine mounted

Gear oil

Filling fluid

Molybdenum disulfide oil

Lubricant

Brake fluid

Special tool

Wheel bearing grease

Tightening torque

Lithium-soap-based grease

Wear limit, clearance

Molybdenum disulfide grease

Engine speed

Silicone grease

Electrical data

Locking agent (LOCTITE®)

Engine oil

Replace the part with a new one.

G

M

BF

B

T R

.

.

LS

M

S

LT

E

New

1

2

3

4

5

6

7

8

9

10

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUST-

MENTS

CHASSIS

ENGINE

COOLING SYSTEM

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLE SHOOTING

TUNING

GENERAL INFORMATION

LOCATION OF IMPORTANT LABELS............................................................1-1

DESCRIPTION..................................................................................................1-2

IDENTIFICATION..............................................................................................1-3

VEHICLE IDENTIFICATION NUMBER ......................................................1-3

ENGINE SERIAL NUMBER........................................................................1-3

MODEL LABEL...........................................................................................1-3

FEATURES.......................................................................................................1-4

OUTLINE OF THE FI SYSTEM ..................................................................1-4

FI SYSTEM.................................................................................................1-5

INCLUDED PARTS...........................................................................................1-6

SIDESTAND ...............................................................................................1-6

SPARK PLUG WRENCH............................................................................1-6

NIPPLE WRENCH......................................................................................1-6

HANDLEBAR PROTECTOR ......................................................................1-6

FUEL HOSE JOINT COVER ......................................................................1-6

COUPLER FOR CONNECTING OPTIONAL PART...................................1-6

IMPORTANT INFORMATION...........................................................................1-8

PREPARATION FOR REMOVAL AND DISASSEMBLY............................1-8

REPLACEMENT PARTS............................................................................1-8

GASKETS, OIL SEALS AND O-RINGS .....................................................1-9

LOCK WASHERS/PLATES AND COTTER PINS ......................................1-9

BEARINGS AND OIL SEALS .....................................................................1-9

CIRCLIPS ...................................................................................................1-9

BASIC SERVICE INFORMATION..................................................................1-10

ELECTRICAL SYSTEM............................................................................1-10

SPECIAL TOOLS ...........................................................................................1-13

CONTROL FUNCTIONS.................................................................................1-18

ENGINE STOP SWITCH..........................................................................1-18

CLUTCH LEVER ......................................................................................1-18

SHIFT PEDAL...........................................................................................1-18

KICKSTARTER LEVER............................................................................1-18

THROTTLE GRIP.....................................................................................1-18

FRONT BRAKE LEVER ...........................................................................1-18

REAR BRAKE PEDAL..............................................................................1-19

STARTER KNOB/IDLE SCREW ..............................................................1-19

1

STARTING AND BREAK-IN...........................................................................1-20

FUEL.........................................................................................................1-20

STARTING A COLD ENGINE ..................................................................1-20

STARTING A WARM ENGINE .................................................................1-21

BREAK-IN PROCEDURES ......................................................................1-21

MAINTENANCE AFTER BREAK-IN ..............................................................1-22

MAJOR MAINTENANCE ..........................................................................1-22

TORQUE-CHECK POINTS.............................................................................1-23

CLEANING AND STORAGE..........................................................................1-25

CLEANING ...............................................................................................1-25

STORAGE ................................................................................................1-25

LOCATION OF IMPORTANT LABELS

1-1

EAS1SL1009

LOCATION OF IMPORTANT LABELS

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

3,4

2

5

1

Premium unleaded

gasoline only.

3FB-2415E-02

4AA-22259-80

WARNING

This unit contains high pressure nitrogen gas.

Mishandling can cause explosion.

Read owner’s manual for instructions.

Do not incinerate, puncture or open.

17D-2812P-00

For use only on a closed course

in sanctioned competition.

This motorcycle does not meet

EPA noise and emissions

standards and is not for general

off-road recreational riding.

DESCRIPTION

1-2

EAS1SL1010

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. Coolant drain bolt

2. Front brake lever

11. Rear brake pedal

3. Throttle grip

12. Air filter

4. Radiator cap

13. Drive chain

5. Fuel tank cap

14. Shift pedal

6. Engine stop switch

15. Oil level check window

7. Fuel tank

16. Starter knob/idle screw

8. Kickstarter lever

17. Front fork

9. Radiator

2

1

6

7 8

9

5 4

3

11

10

17

1615 14

13

12

IDENTIFICATION

1-3

EAS1SL1011

IDENTIFICATION

There are two significant reasons for knowing

the serial number of your vehicle:

1. When ordering parts, you can give the num-

ber to your Yamaha dealer for positive iden-

tification of the model you own.

2. If your vehicle is stolen, the authorities will

need the number to search for and identify

your vehicle.

EAS1SL1012

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is

stamped into the right side of the frame.

EAS1SL1013

ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into

the elevated part of the right-side of the engine.

EAS1SL1014

MODEL LABEL

The model label “1” is affixed to the rear frame.

This information will be needed to order spare

parts.

1

1

1