Table Of Contents - Yamaha YZ450F(W) Owner's Service Manual

Table of Contents

Important Notice6
Fim Machine Weights10
How To Use This Manual12
Finding The Required Page12
Description12
Chapitre13
Manual Format14
How To Read Descriptions14
Illustrated Symbols16
Index18
Table Of Contents20
General Information26
Engine26
Machine Identification28
Vehicle Identification Number28
Engine Serial Number28
Model Label28
Identification De La Moto29
Important Information30
Preparation For Removal And Disassembly30
Wichtige Informationen31
Informations Importantes31
All Replacement Parts32
Gaskets, Oil Seals And O-Rings32
Lock Washers/Plates And Cotter Pins32
Bearings And Oil Seals32
Circlips34
Checking Of Conection36
Verification Des Connexions37
Special Tools38
Outils Speciaux41
Control Functions48
Engine Stop Button48
Clutch Lever48
Kick Starter48
Bedienungselemente Und Deren Funktion49
Fonctions Des Commandes49
Front Brake Lever50
Rear Brake Pedal50
Fuel Cock50
Cold Starter Knob50
Detachable Sidestand52
Valve Joint52
Spark Plug Wrench52
Nipple Wrench52
Fuel54
Carburant55
Starting And Break-In56
Starting A Cold Engine56
Starten Und Einfahren57
Mise En Marche Et Rodage57
Starting A Warm Engine60
Restarting An Engine After A Fall60
The Engine Fails To Start60
Break-In Procedures62
Torque-Check Points62
Points De Verification Des Couples De Serrage65
Anzugsdrehmomente Kontrollieren66
Cleaning And Storage68
Pflege Und Lagerung69
Nettoyage Et Remisage69
General Specifications72
Chassis74
Maintenance Specifications75
Lubrication Chart81
General Torque Specifications89
Definition Of Units89
Caracteristiques Generales90
Caracteristiques D'entretien93
Caracteristiques Generales De Couple107
Definition Des Unites107
Technische Daten108
Allgemeine Technische Daten109
Allgemeine Anzugsmomente125
Lubrication Diagrams126
Diagrammes De Lubrification127
Cable Routing Diagram130
Diagramme D'acheminement Des Cables131
Kabelführungsdiagramme131
Regular Inspection And Adjustments142
Maintenance Intervals142
Controles Et Reglages Periodiques145
Programme D'entretien145
Regelmässige Wartungs- Und Einstellarbeiten148
Wartungsintervalle148
Pre-Operation Inspection And Maintenance151
General Inspection And Maintenance151
Routinekontrolle Vor Fahrtbeginn153
Coolant Level Inspection154
Motor155
Coolant Replacement156
Radiator Cap Inspection158
Handling Notes Of Coolant158
Radiator Cap Opening Pressure Inspection160
Cooling System Inspection160
Clutch Adjustment162
Throttle Cable Adjustment164
Throttle Lubrication164
Hot Starter Lever Adjustment166
Air Filter Cleaning166
Engine Oil Level Inspection170
Engine Oil Replacement174
Pilot Screw Adjustment178
Idle Speed Adjustment180
Valve Clearance Adjustment180
Intake190
Exhaust190
Brake System Air Bleeding194
Fahrwerk195
Front Brake Adjustment196
Rear Brake Adjustment198
Front Brake Pad Inspection And Replacement198
Rear Brake Pad Inspection And Replacement202
Rear Brake Pad Insulator Inspection206
Brake Fluid Level Inspection206
Sprockets Inspection208
Drive Chain Inspection208
Drive Chain Slack Adjustment210
Front Fork Inspection212
Front Fork Oil Seal And Dust Seal Cleaning214
Front Fork Internal Pressure Relieving214
Front Fork Rebound Damping Force Adjustment214
Front Fork Compression Damping Force Adjustment216
Rear Shock Absorber Inspection218
Rear Shock Absorber Spring Preload Adjustment220
Rear Shock Absorber Rebound Damping Force Adjustment222
Rear Shock Absorber Low Compression Damping Force Adjustment224
Rear Shock Absorber High Compression Damping Force Adjustment226
Tire Pressure Check228
Spoke Inspection And Tightening228
Wheel Inspection228
Steering Head Inspection And Adjustment230
Lubrication236
Electrical238
Spark Plug Inspection238
Elektrische Anlage239
Moteur239
Ignition Timing Check240
Seat, Fuel Tank And Side Covers242
Side Cover Removal Points244
Number Plate Removal Points244
Air Scoop Assembly And Installation244
Exhaust Pipe And Silencer246
Exhaust Pipe And Silencer Inspection248
Silencer Fiber Replacement Inspection248
Exhaust Pipe And Silencer Assembly And Installation250
Radiator252
Radiator Removal252
Radiator Handling Note254
Radiator Inspection254
Radiator Assembly And Installation254
Carburetor258
Carburetor Removal258
Carburetor Disassembly260
Carburetor Handling Note264
Pilot Screw Removal Points264
Carburetor Inspection264
Needle Valve Inspection266
Throttle Valve Inspection266
Jet Needle Inspection266
Float Height Inspection268
Float Inspection268
Starter Plunger Inspection270
Accelerator Pump Inspection270
Carburetor Assembly And Installation270
Accelerator Pump Timing Adjustment280
Carburetor Installation280
Camshafts284
Cylinder Head Cover284
Cylinder Head Cover Removal284
Arbres A Cames285
Camshafts Removal286
Camshaft Removal Points288
Camshaft Inspection290
Camshaft Sprocket Inspection292
Decompression System Inspection294
Timing Chain Tensioner Inspection294
Camshaft Assembly And Installation294
Cylinder Head300
Cylinder Head Removal300
Cylinder Head Inspection302
Cylinder Head Assembly And Installation304
Valves And Valve Springs308
Valves And Valve Springs Removal308
Soupapes Et Ressorts De Soupapes309
Ventile Und Ventilfedern309
Valve Lifter And Valve Cotter Removal Points310
Valve Inspection312
Valve Spring Inspection320
Valve Lifter Inspection320
Valves And Valve Springs Assembly And Installation322
Cylinder And Piston326
Cylinder And Piston Removal326
Cylindre Et Piston327
Zylinder Und Kolben327
Piston Removal Points328
Cylinder And Piston Inspection328
Piston Ring Inspection332
Piston Pin Inspection334
Piston Assembly And Installation334
Cylinder Assembly And Installation336
Clutch338
Clutch Removal338
Clutch Boss Removal Points342
Clutch Housing And Boss Inspection342
Primary Driven Gear Inspection342
Clutch Spring Inspection342
Friction Plate Inspection344
Clutch Plate Inspection344
Push Lever Inspection344
Push Rod Inspection344
Push Lever Assembly And Installation346
Clutch Assembly And Installation346
Oil Filter, Water Pump And Crankcase Cover (Right)352
Oil Filter, Water Pump And Crankcase Cover (Right) Removal352
Impeller Shaft Removal Points356
Oil Seal Removal Points356
Impeller Shaft Inspection356
Bearing Inspection358
Oil Seal Inspection358
Oil Seal Assembly And Installation358
Bearing Assembly And Installation358
Impeller Shaft Assembly And Installation360
Crankcase Cover (Right) Assembly And Installation360
Kick Crank Assembly And Installation362
Water Pump Housing Assembly And Installation362
Oil Filter Assembly And Installation364
Balancer366
Balancer Removal366
Balancer, Balancer Drive Gear Ad Balancer Driven Gear Removal Points368
Primary Drive Gear, Balancer Drive Gear And Balancer Driven Gear Inspection368
Balancer Inspection368
Balancer, Balancer Drive Gear And Balancer Driven Gear Assembly And Installation370
Oil Pump372
Oil Pump Removal And Disassembly372
Pompe A Huile373
Oil Pump Inspection376
Oil Pump Assembly And Installation376
Kick Axle And Shift Shaft380
Kick Axle And Shift Shaft Removal380
Arbre De Kick Et Axe De Selecteur381
Kickhebelwelle Und Schaltwelle381
Kick Axle Assembly Removal Points384
Shift Guide And Shift Lever Assembly Removal Points384
Segment Removal Points384
Kick Axle And Ratchet Wheel Inspection384
Kick Gear, Kick Idle Gear And Ratchet Wheel Inspection386
Shift Shaft Inspection386
Shift Guide Ad Shift Lever Assembly Inspection386
Stopper Lever Inspection386
Segment Assembly And Installation388
Stopper Lever Assembly And Installation388
Shift Guide And Shift Lever Assembly And Installation388
Shift Shaft Assembly And Installation390
Kick Axle Assembly And Installation392
Kick Idle Gear Assmebly And Installation394
Cdi Magneto396
Cdi Magneto Removal396
Rotor Removal Points398
Cdi Magneto Inspection398
Woodruff Key Inspection398
Cdi Magneto Assembly And Installation398
Volant Magnetique Cdi399
Engine Removal402
Depose Du Moteur403
Motor Demontieren403
Drive Sprocket Removal Points406
Engine Removal Points406
Engine Installation408
Brake Pedal Assembly And Installation408
Drive Sprocket Assembly And Installation408
Crankcase And Crankshaft412
Crankcase Separation412
Carter Moteur Et Vilebrequin413
Crankcase Bearing416
Crankcase Bearing Removal416
Crankcase Removal Points418
Balancer Shaft Removal Points418
Crankshaft Removal Points420
Crankshaft Bearing Removal Points420
Timing Chain And Timing Chain Guide Inspection420
Crankcase Inspection420
Crankshaft Inspection422
Oil Strainer Inspection422
Crankshaft Bearing Assembly And Installation424
Crankshaft Assembly And Installation424
Transmission, Shift Cam And Shift Fork430
Transmission, Shift Cam And Shift Fork Removal430
Transmission Removal Points432
Gears Inspection432
Shift Fork, Shift Cam And Segment Inspection434
Transmission Assembly And Installation434
Front Wheel And Rear Wheel440
Frot Wheel Removal440
Châssis441
Rear Wheel442
Rear Wheel Removal442
Roue Avant Et Roue Arriere443
Rear Wheel Removal Points444
Wheel Bearing Removal Points444
Wheel Axle Inspection446
Brake Disc Inspection446
Front Wheel Assembly And Installation448
Rear Wheel Assembly And Installation452
Front Brake And Rear Brake458
Front Brake Removal458
Rear Brake Removal460
Frein Avant Et Frein Arriere461
Caliper Disassembly462
Master Cylinder Disassembly464
Brake Fluid Removal Points466
Caliper Piston Removal Points466
Piston Seal Kit Removal Points468
Master Cylinder Inspection468
Caliper Removal Points470
Brake Hose Removal Points470
Caliper Piston Assembly And Installation472
Frot Caliper Assembly And Installation472
Rear Caliper Assembly And Installation474
Master Cylinder Kit Assembly And Installation476
Front Master Cylinder Assembly And Installation478
Rear Master Cylinder Assembly And Installation480
Front Brake Hose Assewmbly And Installation482
Kapitel483
Rear Brake Hose Assembly And Installation484
Brake Fluid486
Front Fork490
Front Fork Removal490
Et Caches Lateraux491
Front Fork Disassembly492
Front Fork Handling Note494
Damper Assembly Removal Points494
Adjuster Removal Points496
Inner Tube Removal Points496
Oil Seal Removal Steps496
Base Valve Removal Points498
Damper Assembly Inspection498
Base Valve Inspection500
Collar Inspection500
Fork Spring Inspection500
Inner Tube Inspection502
Outer Tube Inspection502
Adjuster Inspection502
Front Fork Assembly504
Front Fork Installation520
Handlebar524
Handlebar Removal524
Master Cylinder Removal Points526
Handlebar Inspection526
Handlebar Assembly And Installation526
Steering536
Steering Removal536
Ring Nut Removal Points538
Bearing (Lower) Removal Points538
Bearing Race Removal Points538
Steering Shaft Inspection538
Bearing And Bearing Race Inspection540
Under Bracket Assembly And Installation540
Swingarm546
Swingarm Removal546
Swingarm Disassembly548
Bras Oscillant549
Cap Removal Points550
Bearing Removal Points550
Swingarm Inspection550
Relay Arm Inspection550
Connecting Rod Inspection552
Bearing And Oil Seal Assembly And Installation552
Swingarm Assembly And Installation554
Rear Shock Absorber562
Rear Shock Absorber Removal562
Amortisseur Arriere563
Rear Shock Absorber Handling Note566
Rear Shock Absorber Notes On Disposal (Yamaha Dealers Only)566
Spring (Rear Shock Absorber) Assembly And Installation570
Rear Shock Absorber Assembly And Installation572
Electrical Components And Wiring Diagram576
Drosselklappensensor577
Partie Electrique577
Map-Controlled Cdi Unit578
Function Of Component578
Principal Of 3-Dimensional Control578
3-D Image Map Of Ignition Timing578
Ignition System578
Inspection Steps581
Spark Gap Test584
Coupler, Leads And Ignition Coil Connection Inspection584
"Engine Stop" Button Inspection584
Ignition Coil Inspection586
Neutral Switch Inspection588
Cdi Unit Inspection588
Tps (Throttle Position Sensor) System590
Tps (Throttle Position Sensor) System Handling Note594
Couplers And Leads Connection Inspection594
Tps Cpoil Inspection594
Kabelanschlüsse Kontrollieren595
Tps Replacement And Adjustment596
Carburateur597
Vergaser597
Tps Input Voltage Inspection600
Tuning602
Carburetor Setting602
Atmospheric Conditions And Carburetor Settings604
Effects Of The Setting Parts On The Throttle Valve Opening606
Main System606
Pilot System608
Main Jet Adjustment608
Effects Of Changing The Main Jet (Reference)608
Effects Of Adjusting The Pilot Screw (Reference)610
Pilot Jet Adjustment612
Effects Of Adjusting The Pilot Jet (Reference)612
Jet Needle Groove Positionn Adjustment612
Effects Of Changing The Jet Needle Groove Position (Reference)612
Jet Needle Adjustment614
Effects Of Changing The Jet Needle (Reference)614
Relationship With Throttle Opening616
Leak Jet Adjustment (Accelerator Pump Adjustment)616
Kraftstoff617
Carburettor Setting Parts618
Examples Of Carburetor Depending On Symptom620
Selection Of The Secondary Reduction Ratio (Sprocket)624
Drive And Driven Sprockets Setting Parts626
Tire Pressure626
Front Fork Setting628
Change In Amount And Characteristics Of Fork Oil628
Fourche629
Setting Of Spring After Replacement630
Guidon631
Front Fork Setting Parts632
Rear Suspension Setting632
Choosing Set Length634
Rear Shock Absorber Setting Parts638
Suspension Setting642