Yamaha YZ450FP 2023 Manuals

Manuals and User Guides for Yamaha YZ450FP 2023. We have 1 Yamaha YZ450FP 2023 manual available for free PDF download: Owner's Service Manual

Yamaha YZ450FP 2023 Owner's Service Manual

Yamaha YZ450FP 2023 Owner's Service Manual (388 pages)

Brand: Yamaha | Category: Motorcycle | Size: 26.84 MB

Table of Contents

Table of Contents

9
- Safety Information
  13
- For Safety, be Sure to Obey the Following
  13
- Location of Important Labels
  16
- Description
  17
- Identification
  18
- Vehicle Identification Number
  18
- Engine Serial Number
  18
- Power Tuner
  19
- Fuel Hose Joint Cover
  19
- Nipple Wrench
  19
- Handlebar Protector
  19
- Sidestand
  19
- Included Parts
  19
- Important Information
  21
- Preparation for Removal and Disassembly
  21
- Replacement Parts
  21
- Gaskets, Oil Seals and O-Rings
  21
- Lock Washers/Plates and Cotter Pins
  22
- Bearings and Oil Seals
  22
- Circlips
  22
- Electrical System
  23
- Basic Service Information
  23
- Special Tools
  27
- Instrument and Control Functions
  33
- Engine Stop Switch
  33
- Start Switch
  33
- Launch Control System
  33
- Lap Time Record Mode
  34
- Drive Mode
  34
- Fuel Tank Cap
  35
- Starter Knob
  35
- Rear Brake Pedal
  35
- Front Brake Lever
  35
- Shift Pedal
  35
- Starting and Break-In
  36
- Fuel
  36
- Starting a Cold Engine
  36
- Starting a Warm Engine
  37
- Break-In Procedures
  37
- Engine Starting Precaution
  37
- Maintenance after Break-In
  38
- Major Maintenance
  38
- Air Filter Maintenance
  38
- Torque-Check Points
  39
- Motorcycle Care and Storage
  41
- Care
  41
- Storage
  42
Specifications

45
- General Specifications
  46
- Engine Specifications
  47
- Chassis Specifications
  52
- Electrical Specifications
  53
- General Tightening Torque Specifications
  54
- Tightening Torques
  54
- Engine Tightening Torques
  55
- Chassis Tightening Torques
  58
- Cable Routing Diagram
  62
Periodic Checks and Adjustments

77
- Maintenance Intervals
  80
- General Inspection and Maintenance
  84
- Pre-Operation Inspection and Maintenance
  84
- Adjusting the Valve Clearance
  85
- Engine
  85
- Valve Clearance Shim Chart
  88
- Checking the Engine Idling Speed
  90
- Checking the Throttle Grip
  90
- Checking the Engine Oil Level
  91
- Checking the Spark Plug
  91
- Changing the Engine Oil
  92
- Adjusting the Clutch Lever Free Play
  93
- Adjusting the Clutch Lever Position
  94
- Cleaning the Air Filter Element
  94
- Checking the Fuel Line
  96
- Checking the Throttle Body Joint
  96
- Checking the Cylinder Head Breather Hose
  97
- Checking the Exhaust System
  97
- Checking the Coolant Level
  99
- Changing the Coolant
  100
- Checking the Cooling System
  100
- Adjusting the Front Disc Brake
  102
- Adjusting the Rear Disc Brake
  102
- Chassis
  102
- Checking the Brake Fluid Level
  102
- Checking the Front Brake Hose
  103
- Checking the Front Brake Pads
  103
- Checking the Rear Brake Pads
  103
- Bleeding the Hydraulic Brake System
  104
- Checking the Brake Operation
  104
- Checking the Rear Brake Hose
  104
- Drive Chain Slack
  105
- Checking and Adjusting the Steering Head
  106
- Adjusting the Front Fork Legs
  107
- Checking the Front Fork Legs
  107
- Lubricating the Steering Head
  107
- Adjusting the Rear Shock Absorber Assembly
  109
- Checking the Rear Shock Absorber Assembly
  109
- Checking the Connecting Arm and Relay Arm
  111
- Checking the Swingarm Operation
  111
- Checking the Tires
  111
- Lubricating the Swingarm Pivot
  111
- Checking and Lubricating the Cables
  112
- Checking and Tightening the Spokes
  112
- Checking the Chassis Fasteners
  112
- Checking the Wheel Bearings
  112
- Checking the Wheels
  112
- Lubricating the Brake Lever
  113
- Lubricating the Clutch Lever
  113
- Lubricating the Pedal
  113
- Checking and Charging the Battery
  114
- Checking the Fuses
  114
- Electrical System
  114
Chassis

115
- General Chassis
  120
- Installing the Shroud
  120
- Removing the Number Plate
  120
- Removing the Seat
  120
- Installing the Side Cover
  121
- Removing the Side Cover
  121
- Front Wheel
  122
- Assembling the Front Wheel
  124
- Checking the Front Wheel
  124
- Disassembling the Front Wheel
  124
- Removing the Front Wheel
  124
- Installing the Front Wheel
  125
- Checking and Replacing the Rear Wheel Sprocket
  129
- Checking the Rear Wheel
  129
- Disassembling the Rear Wheel
  129
- Rear Wheel
  129
- Removing the Rear Wheel
  129
- Assembling the Rear Wheel
  130
- Installing the Rear Wheel
  130
- Front Brake
  133
- Checking the Front Brake Disc
  136
- Introduction
  136
- Replacing the Front Brake Pads
  136
- Assembling the Front Brake Caliper
  138
- Checking the Front Brake Caliper
  138
- Disassembling the Front Brake Caliper
  138
- Removing the Front Brake Caliper
  138
- Installing the Front Brake Caliper
  139
- Assembling the Front Brake Master Cylinder
  140
- Checking the Front Brake Master Cylinder
  140
- Removing the Front Brake Master Cylinder
  140
- Installing the Front Brake Master Cylinder
  141
- Rear Brake
  143
- Checking the Rear Brake Disc
  148
- Introduction
  148
- Replacing the Rear Brake Pads
  148
- Checking the Rear Brake Caliper
  150
- Disassembling the Rear Brake Caliper
  150
- Removing the Rear Brake Caliper
  150
- Assembling the Rear Brake Caliper
  151
- Installing the Rear Brake Caliper
  151
- Assembling the Rear Brake Master Cylinder
  152
- Checking the Rear Brake Master Cylinder
  152
- Removing the Rear Brake Master Cylinder
  152
- Installing the Rear Brake Master Cylinder
  153
- Checking the Handlebar
  157
- Installing the Handlebar
  157
- Removing the Handlebar
  157
- Front Fork
  162
- Disassembling the Front Fork Legs
  164
- Removing the Front Fork Legs
  164
- Checking the Front Fork Legs
  165
- Assembling the Front Fork Legs
  166
- Installing the Front Fork Legs
  172
- Steering Head
  174
- Checking the Steering Head
  176
- Installing the Steering Head
  176
- Removing the Lower Bracket
  176
- Rear Shock Absorber Assembly
  179
- Checking the Rear Shock Absorber Assembly
  182
- Disposing of a Rear Shock Absorber
  182
- Handling the Rear Shock Absorber
  182
- Removing the Rear Shock Absorber Assembly
  182
- Checking the Connecting Arm and Relay Arm
  183
- Installing the Connecting Arm
  183
- Installing the Relay Arm
  183
- Installing the Rear Shock Absorber Assembly
  184
- Swingarm
  186
- Checking the Swingarm
  188
- Installing the Swingarm
  188
- Removing the Swingarm
  188
- Chain Drive
  190
- Checking the Drive Chain
  191
- Removing the Drive Chain
  191
- Checking the Drive Sprocket
  192
- Checking the Rear Wheel Sprocket
  192
- Installing the Drive Chain
  192
Engine

195
- Engine Oil Lubrication Chart
  197
- Lubrication System Chart and Diagrams
  197
- Engine Removal
  198
- Installing the Engine
  203
- Removing the Engine
  203
- Installing the Exhaust Pipe and Muffler
  204
- Camshaft
  206
- Checking the Camshaft
  208
- Removing the Camshaft
  208
- Checking the Timing Chain and Camshaft Sprocket
  209
- Checking the Decompression System
  210
- Checking the Timing Chain Tensioners
  210
- Installing the Camshafts
  210
- Cylinder Head
  213
- Checking the Cylinder Head
  215
- Checking the Timing Chain Guide (Intake Side)
  215
- Installing the Cylinder Head
  215
- Removing the Cylinder Head
  215
- Valves and Valve Springs
  218
- Removing the Valves
  220
- Checking the Valves and Valve Guides
  221
- Checking the Valve Seats
  222
- Checking the Valve Springs
  223
- Checking the Valve Lifters
  224
- Installing the Valves
  224
- Cylinder and Piston
  226
- Checking the Cylinder and Piston
  227
- Removing the Piston
  227
- Checking the Piston Rings
  228
- Checking the Piston Pin
  229
- Installing the Piston and Cylinder
  229
- Generator
  231
- Checking the Generator
  234
- Checking the Woodruff Key
  234
- Installing the Generator
  234
- Removing the Generator
  234
- Electric Starter
  236
- Assembling the Starter Motor
  238
- Checking the Starter Motor
  238
- Checking the Clutch Plates
  244
- Checking the Clutch Spring
  244
- Checking the Friction Plates
  244
- Clutch
  244
- Removing the Clutch
  244
- Checking the Collar
  245
- Checking the Pressure Plate
  245
- Checking the Primary Drive Gear
  245
- Checking the Primary Driven Gear
  245
- Checking the Push Lever Shaft
  245
- Checking the Push Rod
  245
- Assembling the Clutch Release
  246
- Installing the Clutch
  246
- Installing the Clutch Release
  246
- Checking the Shift Shaft
  252
- Checking the Stopper Lever
  252
- Installing the Shift Shaft
  252
- Removing the Segment
  252
- Shift Shaft
  252
- Starter Clutch
  256
- Checking the Starter Clutch
  257
- Installing the Balancer Gear
  257
- Removing the Balancer Gear
  257
- Assembling the Oil Pump
  260
- Checking the Oil Pump
  260
- Installing the Oil Pump
  260
- Oil Pump
  260
- Crankcase
  261
- Checking the Crankcase
  265
- Checking the Timing Chain Guide (Exhaust Side)
  265
- Disassembling the Crankcase
  265
- Assembling the Crankcase
  266
- Checking the Oil Strainer
  266
- Crankshaft and Balancer Shaft
  268
- Checking the Crankshaft
  269
- Removing the Crankshaft
  269
- Installing the Crankshaft
  270
- Transmission
  271
- Checking the Shift Drum Assembly
  274
- Checking the Shift Forks
  274
- Removing the Transmission
  274
- Checking the Transmission
  275
- Installing the Transmission
  275
Cooling System

279
- Cooling System Diagrams
  280
- Radiator
  281
- Checking the Radiator
  283
- Installing the Radiator
  283
- Water Pump
  285
- Assembling the Water Pump
  287
- Checking the Water Pump
  287
- Disassembling the Water Pump
  287
Fuel System

289
- Checking the Fuel Pump Body
  291
- Checking the Fuel Pump Operation
  291
- Fuel Tank
  291
- Installing the Fuel Pump
  291
- Removing the Fuel Pump
  291
- Removing the Fuel Tank
  291
- Installing the Fuel Tank
  292
- Throttle Body
  293
- Checking the Injector
  296
- Checking the Throttle Body
  296
- Adjusting the Throttle Position Sensor
  297
- Checking the Fuel Pressure
  297
- Installing the Air Filter Case Assembly Bracket
  298
Electrical System

299
- Circuit Diagram
  300
- Ignition System
  300
- Troubleshooting
  302
- Circuit Diagram
  306
- Electric Starting System
  306
- Troubleshooting
  308
- Charging System
  310
- Circuit Diagram
  310
- Troubleshooting
  312
- Circuit Diagram
  314
- Fuel Injection System
  314
- Connecting the Yamaha Diagnostic Tool
  316
- Yamaha Diagnostic Tool
  316
- Troubleshooting Details (Fault Code)
  318
- Circuit Diagram
  340
- Fuel Pump System
  340
- Troubleshooting
  342
- Electrical Components
  343
- Checking the Switches
  344
- Checking and Charging the Battery
  346
- Checking the Fuses
  346
- Checking the Relay Unit (Diode)
  348
- Checking the Relays
  348
- REPLACING the ECU (Engine Control Unit)
  348
- Checking the Ignition Coil
  349
- Checking the Ignition Spark Gap
  349
- Checking the Spark Plug Cap
  349
- Checking the Crankshaft Position Sensor
  350
- Checking the Lean Angle Sensor
  350
- Checking the Starter Motor Operation
  350
- Checking the Rectifier/Regulator
  351
- Checking the Stator Coil
  351
- Checking the Coolant Temperature Sensor
  352
- Checking the Throttle Position Sensor Input Voltage
  352
- Checking the Gear Position Switch
  353
- Checking the Intake Air Temperature Sensor
  353
- Checking the Injector
  354
- Checking the Indicator Light
  355
Troubleshooting

357
Tuning

373
- Chassis
  374
- Selection of the Secondary Reduction Ratio (Sprocket)
  374
- Tire Pressure
  374
- Change in Amount and Characteristics of Fork Oil
  375
- Front Fork Setting
  375
- Setting of Spring after Replacement
  375
- Choosing Set Length
  376
- Front Fork Setting Parts
  376
- Rear Suspension Setting
  376
- Rear Shock Absorber Setting Parts
  377
- Setting of Spring after Replacement
  377
- Suspension Setting (Front Fork)
  379
- Suspension Setting (Rear Shock Absorber)
  380

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