Yamaha YZ450F 2021 Motorcycle Manuals

Yamaha YZ450F 2021 Motorcycle Manuals

Manuals and User Guides for Yamaha YZ450F 2021 Motorcycle. We have 1 Yamaha YZ450F 2021 Motorcycle manual available for free PDF download: Owner's Service Manual

Yamaha YZ450F 2021 Owner's Service Manual

Yamaha YZ450F 2021 Owner's Service Manual (368 pages)

Brand: Yamaha | Category: Motorcycle | Size: 24 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
- Included Parts
  19
  - Sidestand
    19
  - Nipple Wrench
    19
  - Handlebar Protector
    19
  - Fuel Hose Joint Cover
    19
  - Power Tuner
    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
- Basic Service Information
  23
  - Electrical System
    23
- Special Tools
  27
- Instrument and Control Functions
  33
  - Engine Stop Switch
    33
  - Start Switch
    33
  - Launch Control Switch
    33
  - Mode Switch
    33
  - Shift Pedal
    34
  - Front Brake Lever
    34
  - Rear Brake Pedal
    34
  - Starter Knob
    34
  - Fuel Tank Cap
    35
- Fuel
  36
  - Starting a Cold Engine
    36
  - Starting a Warm Engine
    37
  - Break-In Procedures
    37
  - Engine Starting Precaution
    37
- Starting and Break-In
  36
- 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
  - Tightening Torques
    54
- General Tightening Torque Specifications
  54
  - Engine Tightening Torques
    55
  - Chassis Tightening Torques
    58
- Cable Routing Diagram
  62
Periodic Checks and Adjustments

75
- Maintenance Intervals
  77
- Pre-Operation Inspection and Maintenance
  
  81
  - General Inspection and Maintenance
    81
  - Adjusting the Valve Clearance
    82
  - Engine
    82
  - Valve Clearance Shim Chart
    85
  - Checking the Engine Idling Speed
    87
  - Checking the Throttle Grip
    87
  - Checking the Spark Plug
    88
  - Changing the Engine Oil
    89
  - Checking the Engine Oil Level
    89
  - Adjusting the Clutch Lever Free Play
    91
  - Adjusting the Clutch Lever Position
    91
  - Cleaning the Air Filter Element
    91
  - Checking the Fuel Line
    93
  - Checking the Throttle Body Joint
    93
  - Checking the Cylinder Head Breather Hose
    94
  - Checking the Exhaust System
    94
  - Checking the Coolant Level
    96
  - Changing the Coolant
    97
  - Checking the Cooling System
    97
  - Adjusting the Front Disc Brake
    99
    
    Adjusting the Rear Disc Brake
    99
    
    Checking the Brake Fluid Level
    100
    
    Checking the Front Brake Hose
    100
    
    Checking the Front Brake Pads
    100
    
    Checking the Rear Brake Pads
    100
    
    Bleeding the Hydraulic Brake System
    101
    
    Checking the Brake Operation
    101
    
    Checking the Rear Brake Hose
    101
    
    Drive Chain Slack
    102
    
    Checking and Adjusting the Steering Head
    103
    
    Adjusting the Front Fork Legs
    104
    
    Checking the Front Fork Legs
    104
    
    Lubricating the Steering Head
    104
    
    Adjusting the Rear Shock Absorber Assembly
    106
    
    Checking the Rear Shock Absorber Assembly
    106
    
    Checking the Connecting Arm and Relay Arm
    108
    
    Checking the Swingarm Operation
    108
    
    Checking the Tires
    108
    
    Lubricating the Swingarm Pivot
    108
    
    Checking and Lubricating the Cables
    109
    
    Checking and Tightening the Spokes
    109
    
    Checking the Chassis Fasteners
    109
    
    Checking the Wheel Bearings
    109
    
    Checking the Wheels
    109
    
    Lubricating the Brake Lever
    110
    
    Lubricating the Clutch Lever
    110
    
    Lubricating the Pedal
    110
- Chassis
  
  99
  - Checking and Charging the Battery
    111
  - Checking the Fuses
    111
  - Checking the Ignition Timing
    111
- Electrical System
  
  111
Chassis

113
- General Chassis
  
  117
  - Removing the Seat
    117
  - Removing the Number Plate
    117
  - Installing the Air Scoop
    117
  - Removing the Side Cover
    118
  - Installing the Side Cover
    118
  - Front Wheel
    119
- Removing the Front Wheel
  
  120
  - Disassembling the Front Wheel
    120
  - Checking the Front Wheel
    120
  - Assembling the Front Wheel
    121
  - Installing the Front Wheel
    121
  - Rear Wheel
    123
- Removing the Rear Wheel
  
  124
  - Disassembling the Rear Wheel
    124
  - Checking the Rear Wheel
    124
  - Checking and Replacing the Rear Wheel Sprocket
    124
  - Assembling the Rear Wheel
    125
  - Installing the Rear Wheel
    125
- Front Brake
  
  128
- Rear Brake
  
  138
  - Introduction
    142
  - Checking the Rear Brake Disc
    142
  - Replacing the Rear Brake Pads
    142
  - Removing the Rear Brake Caliper
    144
  - Disassembling the Rear Brake Caliper
    144
  - Checking the Rear Brake Caliper
    144
  - Assembling the Rear Brake Caliper
    145
  - Installing the Rear Brake Caliper
    145
  - Removing the Rear Brake Master Cylinder
    146
  - Checking the Rear Brake Master Cylinder
    146
  - Assembling the Rear Brake Master Cylinder
    146
  - Installing the Rear Brake Master Cylinder
    147
  - Removing the Handlebar
    151
  - Checking the Handlebar
    151
  - Installing the Handlebar
    151
- Front Fork
  
  156
  - Removing the Front Fork Legs
    158
  - Disassembling the Front Fork Legs
    158
  - Checking the Front Fork Legs
    159
  - Assembling the Front Fork Legs
    160
  - Installing the Front Fork Legs
    167
- Steering Head
  
  169
  - Removing the Lower Bracket
    170
  - Checking the Steering Head
    170
  - Installing the Steering Head
    170
- Rear Shock Absorber Assembly
  
  173
- Swingarm
  
  179
  - Removing the Swingarm
    180
  - Checking the Swingarm
    180
  - Installing the Swingarm
    180
- Chain Drive
  
  182
  - Removing the Drive Chain
    183
  - Checking the Drive Chain
    183
  - Checking the Drive Sprocket
    184
  - Checking the Rear Wheel Sprocket
    184
  - Installing the Drive Chain
    184
Engine

185
- Lubrication System Chart and Diagrams
  
  187
  - Engine Oil Lubrication Chart
    187
  - Lubrication Diagrams
    188
- Engine Removal
  
  192
  - Removing the Engine
    196
  - Installing the Engine
    196
  - Installing the Exhaust Pipe and Muffler
    197
  - Camshaft
    199
  - Removing the Camshaft
    201
  - Checking the Camshaft
    202
  - Checking the Timing Chain and Camshaft Sprocket
    203
  - Checking the Timing Chain Tensioners
    203
  - Checking the Decompression System
    203
  - Installing the Camshafts
    203
- Cylinder Head
  
  207
- Valves and Valve Springs
  
  213
  - Removing the Valves
    213
  - Checking the Valves and Valve Guides
    214
  - Checking the Valve Seats
    215
  - Checking the Valve Springs
    216
  - Checking the Valve Lifters
    217
  - Installing the Valves
    217
- Cylinder and Piston
  
  219
  - Removing the Piston
    220
  - Checking the Cylinder and Piston
    220
  - Checking the Piston Rings
    221
  - Checking the Piston Pin
    222
  - Installing the Piston and Cylinder
    222
  - Generator
    224
  - Removing the Generator
    225
  - Checking the Generator
    225
  - Checking the Woodruff Key
    225
  - Installing the Generator
    225
- Starter Clutch
  
  227
  - Checking the Starter Clutch
    228
- Electric Starter
  
  229
  - Checking the Starter Motor
    231
  - Assembling the Starter Motor
    231
  - Removing the Clutch
    236
  - Checking the Friction Plates
    236
  - Checking the Clutch Plates
    236
  - Checking the Clutch Springs
    236
  - Checking the Clutch Housing
    236
  - Checking the Clutch Boss
    237
  - Checking the Pressure Plate
    237
  - Checking the Push Lever Shaft
    237
  - Checking the Push Rods
    237
  - Checking the Primary Drive Gear
    237
  - Checking the Primary Driven Gear
    237
  - Installing the Clutch
    237
- Shift Shaft
  
  241
  - Removing the Segment
    242
  - Checking the Shift Shaft
    242
  - Checking the Stopper Lever
    242
  - Installing the Shift
    242
- Oil Pump
  
  245
  - Removing the Oil Pump
    247
  - Checking the Oil Pump
    247
  - Assembling the Oil Pump
    247
  - Installing the Oil Pump
    248
- Crankcase
  
  250
  - Disassembling the Crankcase
    252
  - Checking the Timing Chain Guide (Exhaust Side)
    252
  - Checking the Crankcase
    252
  - Assembling the Crankcase
    253
- Crankshaft and Balancer Shaft
  
  254
  - Removing the Crankshaft
    255
  - Checking the Crankshaft
    255
  - Installing the Crankshaft
    256
- Transmission
  
  257
  - Removing the Transmission
    258
  - Checking the Shift Forks
    258
  - Checking the Shift Drum Assembly
    258
  - Checking the Transmission
    258
  - Installing the Transmission
    259
Cooling System

263
- Cooling System Diagrams
  
  264
- Radiator
  
  265
  - Checking the Radiator
    267
  - Installing the Radiator
    267
- Water Pump
  
  269
  - Disassembling the Water Pump
    270
  - Checking the Water Pump
    270
  - Assembling the Water Pump
    270
Fuel System

273
- Fuel Tank
  274
- Fuel Tank
  274
- Checking the Fuel Pump Body
  275
- Checking the Fuel Pump Operation
  275
- Installing the Fuel Pump
  275
- Removing the Fuel Pump
  275
- Removing the Fuel Tank
  275
- Installing the Fuel Tank
  276
- Throttle Body
  277
- Checking the Fuel Pressure
  280
- Checking the Injector
  280
- Checking the Throttle Body
  280
- Adjusting the Throttle Position Sensor
  281
Electrical System

283
- Ignition System
  
  284
  - Circuit Diagram
    284
  - Troubleshooting
    286
- Electric Starting System
  
  290
  - Circuit Diagram
    290
  - Troubleshooting
    292
- Charging System
  
  294
  - Circuit Diagram
    294
  - Troubleshooting
    296
- Fuel Injection System
  
  298
  - Circuit Diagram
    298
  - Yamaha Diagnostic Tool
    300
  - Connecting the Yamaha Diagnostic Tool
    300
  - Troubleshooting Details (Fault Code)
    302
- Fuel Pump System
  
  322
  - Circuit Diagram
    322
  - Troubleshooting
    324
- Electrical Components
  
  325
  - Checking the Switches
    326
  - Checking the Fuses
    328
  - Checking and Charging the Battery
    328
  - Checking the Relays
    330
  - Checking the Relay Unit (Diode)
    330
  - Checking the Ignition Spark Gap
    331
  - Checking the Spark Plug Cap
    331
  - Checking the Ignition Coil
    332
  - Checking the Crankshaft Position Sensor
    332
  - Checking the Lean Angle Sensor
    333
  - Checking the Starter Motor Operation
    333
  - Checking the Stator Coil
    333
  - Checking the Rectifier/Regulator
    333
  - Checking the Coolant Temperature Sensor
    334
  - Checking the Throttle Position Sensor Input Voltage
    335
  - Checking the Intake Air Temperature Sensor
    335
  - Checking the Gear Position Switch
    336
  - Checking the Injector
    336
Troubleshooting

337
- Troubleshooting
  
  338
- Self-Diagnostic Function and Diagnostic Code Table
  
  349
Tuning

353
- Chassis
  354
- Drive and Rear Wheel Sprockets Setting Parts
  354
- Selection of the Secondary Reduction Ratio (Sprocket)
  354
- Tire Pressure
  354
- Change in Amount and Characteristics of Fork Oil
  355
- Front Fork Setting
  355
- Setting of Spring after Replacement
  355
- Choosing Set Length
  356
- Front Fork Setting Parts
  356
- Rear Suspension Setting
  356
- Rear Shock Absorber Setting Parts
  357
- Suspension Setting (Front Fork)
  359
- Suspension Setting (Rear Shock Absorber)
  360

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