2006 YZ four stroke motocross All new YZ450F YZ450F ENGINE 5-speed transmission All-new dry sump lubrication system

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1 2006 YZ four stroke motocross Yamaha s off road competition range gets even stronger for 2006, with the arrival of the radical new second generation YZ450F and YZ250F four strokes. Based on the machinery that has dominated the MX1 World Championship as well as taking a number of MX2 GP wins the 06 Yamaha four strokes come with a pedigree that few other bikes can even come close to matching. Featuring new aluminium frames, sophisticated new suspension systems including titanium rear springs, and radical new factory bike inspired airflow bodywork, the 2006 YZ450F and YZ250F set new standards in performance, design and quality. All new YZ450F Yamaha s four stroke motocross bikes have made a significant impact in the off road world. Since the new millennium Yamaha s YZF models have dominated motocross at every level and the factory version, which is actually a modified production bike, has taken the legendary Stefan Everts to four MX World Championships in a row. For the 2006 season the new Yamaha s YZ450F benefits from radical changes to the engine and chassis. Powering the second generation YZ450F is a new engine equipped with a 5-speed transmission and a compact new dry sump lubrication system for even higher levels of race-winning performance. This 450cc engine is housed in a totally new factory-bike derived lightweight aluminium frame that elevates handling performance to a whole new level. Stylish new bodywork gives the YZ450F a more radical and aggressive factory bike look, and improved ergonomics are designed to give enhanced rider mobility. YZ450F ENGINE The YZ450F 5-valve engine is famous for its massive power output, and for 2006 our engineers have focused on enhancing controllability and improving the powerplant s overall performance characteristics. This has been achieved through changes to the transmission, and modifications to the engine s weight distribution in the all-new aluminium chassis in order to centralise mass for sharper handling. 5-speed transmission One of the most significant changes to be found on the latest model is the use of a new 5-speed transmission, a feature which makes the new generation YZ450F even more competitive over a wider range of track types. On the new 2006 model, 1st and 3rd gears use the same ratios as the 05 machine, while 2nd is slightly higher and 4th a little lower. Running with a ratio of 0.952, the new 5th gear ensures that the YZ450F rider has a more versatile transmission that is built to allow the delivery of optimum power on everything from tight motocross tracks through to high speed hare and hounds type events. All-new dry sump lubrication system The 2006 model also benefits from a totally new dry sump lubrication system which features an integrated oil tank in the newly designed crankcase. This new system ensures excellent engine lubrication, and also helps to centralise mass for easier and lighter handling qualities. By eliminating the need for the exposed external pipes associated with the previous oil in frame tank, the new dry sump system reduces the possibility of accidental damage caused by flying debris.

2 The new lubrication system also includes a new piston cooler which sprays oil onto the cylinder to give even more consistent engine performance at high rpm, while the delivery pipe taking oil to the cylinder head also lubricates the cylinder wall for even more efficient engine operation. More upright cylinder inclination The balance of the 2006 bike has been idealised by a change in the inclination of the cylinder. Compared to the previous model, the new YZ450F cylinder block has a more upright layout, sloping forward at only 4.5 degrees from the vertical, to bring the machine s centre of gravity closer to the rider. Together with the use of a new aluminium chassis, this idealised weight distribution makes for lighter handling performance and more agile cornering qualities. Improved balancer design Another of the many changes to be made to the 450cc 5-valve engine for 2006 is the use of more efficient balancer design an improvement that has been made possible by the fitment of a new high strength conrod and piston, as well as the use of a newly designed crankshaft featuring an optimised inertial mass. Running on ball bearings and featuring a larger balance shaft gear for reduced mechanical noise, this more effective design reduces engine vibration while at the same time making the YZ450F s outstanding power output easier to use. New design intake and revised carburettor settings The 06 machine is equipped with a newly designed air cleaner box and side cover duct which have been designed to accommodate the more upright engine layout. Together with a reshaped inlet port, these changes help contribute to the engine s excellent intake efficiency. To complement the new intake design the FCR39 carburettor runs with new settings, and also features a leak jet-type acceleration pump which delivers very linear throttle response by maintaining an optimum air/fuel mix. Also new for 06 is a carburettor heater which ensures efficient intake processes over a wide range of operating conditions. New compact radiator design The new single core radiators are lighter, smaller and more efficient than the previous design, and feature a 20mm reduction in overall height, as well as a 10mm decrease in depth. Newly designed air induction fins deliver an improved flow of air to the new radiators, allowing the new system to achieve the same high levels of cooling efficiency as the 05 model s larger design while a 21% reduction in coolant capacity on the 2006 model reduces overall weight. New exhaust and silencer Matching the revised incline of the cylinder engine is a new exhaust and silencer which offers improved mass centralisation and complies with 2006 FIM regulations. The new exhaust also incorporates a small expansion chamber which is designed to achieve smoother and deeper power characteristics.

3 Further engine changes Other detail changes for 06 include a new CDI with revised ignition advance characteristics designed to give even better driveability. To help reduce weight, the 5-valve cylinder head has been redesigned, and for improved serviceability the cylinder head retaining bolts on the left side are now screwed down into the cylinder block, rather than upwards into the cylinder head. Finally, a new kickstart is fitted. Engine Technical Highlights 4-stroke DOHC liquid cooled engine Bore x stroke 95.0 x 63.4mm 5-valve cylinder head More upright cylinder position New 5-speed close-ratio transmission New dry sump lubrication system with integral oil tank in crankcase Elimination of external oil pipes New high strength piston and con rod New crankshaft with optimised inertial mass More efficient engine balancer New heated carburettor with revised settings New lighter and more compact radiators Modified air box New exhaust with expansion chamber New shape silencer Redesigned kickstart New CDI with revised ignition advance YZ450F CHASSIS All-new lightweight aluminium frame The new YZ450F is equipped with a beautifully-finished semi-double cradle frame consisting of nine individual parts made from four different types of aluminium, these being forged, cast, pipe and extruded. By using these four different types of aluminium in the new frame, Yamaha s designers have succeeded in creating an extremely light, strong and well balanced structure. A certain amount of balanced flex has been built into the new frame s vertical plane, and this characteristic enhances the feedback felt by the rider. This combination of vertical flex together with very high levels of lateral and torsional rigidity give good straight line stability, responsive handling and reduced rider fatigue, making the new YZ450F frame one of the most high performance designs in the class. Advanced welding techniques have been used in the manufacture of this new frame, resulting in a structure that not only delivers exceptional handling performance, but also has a functional beauty and a high level of finish. Combined with the idealised weight distribution, created by the more upright cylinder, this highly rigid lightweight frame and modified aluminium subframe give superior

4 handling characteristics for improved cornering performance and excellent overall stability. Lower machine height The new frame has revised dimensions, and the result of this is a more compact chassis with improved mass centralisation, as well as a lower machine height. With its reduced overall weight and lower overall height, the 2006 YZ450F has easier and lighter handling characteristics, making it a much more rider friendly package. Revalved front forks Newly designed Kayaba 48mm front forks have been developed to complement the characteristics of the new aluminium frame. Significant changes have been made to the internals, and the new system utilises new valving, a smaller diameter cylinder, repositioned springs and low friction oil seals. Damping force is now controlled by piston speed (as compared to piston position on the 05 model) to give improved damping and shock absorption characteristics throughout the entire fork stroke. New triple clamps and wider fork pitch The 2006 front suspension system runs with a newly designed cast aluminium upper triple clamp and a forged lower triple clamp that offer higher levels of vertical and torsional rigidity. Together with a wider fork pitch, these changes deliver improved feel and better handling characteristics. First ever titanium spring shock absorber on a Yamaha For 2006 Yamaha s engineers have gone all out to produce one of the finest handling production four strokes available today, and the new rear shock underlines the very close relationship between the production machine and our factory race bikes. The all-new shock absorber is equipped with a lightweight titanium spring weighing 500g less than a steel unit the first time titanium has ever been used on a production Yamaha rear suspension system. Also new for 2006 is a larger diameter 18mm damper rod for increased strength, as well as a 30% increase in gas chamber capacity for more stable performance. A new low friction Kashima coating is also featured on internal components for smoother operation, and a revised linkage lever ratio ensures outstanding cushioning characteristics. Never before has the production YZ450F been so close to the specification of Yamaha s MX1 World Championship winning machinery. Redesigned high rigidity swingarm As well as the fitment of a new titanium spring shock and revised linkage lever ratio, the rear suspension system features a new higher rigidity swingarm that has been made using a remarkably intricate hydroforming system. This allows the manufacture of a light, strong and well balanced swingarm, structures which offer improved traction and more consistent suspension performance. Totally restyled bodywork Together with the beautifully finished aluminium frame, the new airflow design bodywork totally transforms the look of the YZ450F, making it one of the most aggressively styled dirt bikes in the category.

5 Every major piece of bodywork has been redesigned, including the fuel tank, radiator shrouds, front and rear fenders, sidepanels and front number plate. The seat shape and depth has also been changed, and the new design allows for easy bodyweight shifting, as do the repositioned footrests. With its lower overall height, centralised mass and class leading finish, the all-new YZ450F is going to be the main contender in the stroke class. Taper-type handlebars with adjustable mounts New taper-style handlebars are fitted as original equipment, and these new bars are mounted to adjustable clamps which allow the rider to opt for the standard position, or move the bars forward by 10mm. The new taper-style handlebars are also marked with a choice of five position settings, so that riders can choose the set-up that best suits their riding style. Easy-fit rear wheel collars As well as being amongst the fastest bikes on the track, the new YZ450F is also quick and to service, thanks to new rear wheel collars featuring a specially-chamfered profiled for easier rear wheel removal and installation. Compact rear brake caliper To accommodate the new muffler there s a reshaped rear brake caliper, and for improved protection from deep ruts and stones the rear disc protector has been redesigned. Chassis Technical Highlights All-new lightweight aluminium frame Modified aluminium subframe Newly designed front forks with new internals New triple clamps and wider pitch forks New rear shock with titanium spring Higher rigidity swingarm Revised linkage ratios Adjustable taper-type handlebars Totally redesigned airflow design bodywork New seat Repositioned footrests Easy fit rear wheels with new collars Modified rear brake caliper and disc protector

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