Yamaha YZ450FF Manuals

Manuals and User Guides for Yamaha YZ450FF. We have 1 Yamaha YZ450FF manual available for free PDF download: Owner's Service Manual

Yamaha YZ450FF Owner's Service Manual

Yamaha YZ450FF Owner's Service Manual (360 pages)

2015

Brand: Yamaha | Category: Motorcycle | Size: 11.35 MB

Table of Contents

Table of Contents

11
- Important Manual Information
  6
- Safety Information
  7
- How to Use this Manual
  8
- General Information
  13
  - Location of Important Labels
    15
  - Description
    18
  - Identification
    19
    
    Vehicle Identification Number
    19
    
    Engine Serial Number
    19
    
    Model Label
    19
  - Features
    20
    
    Outline of the Fi System
    20
    
    Fi System
    21
  - Included Parts
    22
    
    Sidestand
    22
    
    Spark Plug Wrench
    22
    
    Nipple Wrench
    22
    
    Handlebar Protector
    22
    
    Fuel Hose Joint Cover
    22
    
    Coupler for Connecting Optional Part
    22
  - Important Information
    24
    
    Preparation for Removal and Disassembly
    24
    
    Replacement Parts
    24
    
    Gaskets, Oil Seals and O-Rings
    25
    
    Lock Washers/Plates and Cotter Pins
    25
    
    Bearings and Oil Seals
    25
    
    Circlips
    25
  - Basic Service Information
    26
    
    Electrical System
    26
  - Special Tools
    29
  - Control Functions
    34
    
    Engine Stop Switch
    34
    
    Clutch Lever
    34
    
    Shift Pedal
    34
    
    Kickstarter Lever
    34
    
    Throttle Grip
    34
    
    Front Brake Lever
    34
    
    Rear Brake Pedal
    35
    
    Starter Knob/Idle Screw
    35
    
    Fuel Tank Cap
    35
  - Starting and Break-In
    36
    
    Fuel
    36
    
    Starting a Cold Engine
    36
    
    Starting a Warm Engine
    37
    
    Break-In Procedures
    37
  - Maintenance after Break-In
    38
    
    Major Maintenance
    38
  - Torque-Check Points
    39
  - Cleaning and Storage
    41
    
    Cleaning
    41
    
    Storage
    41
Specifications

43
- General Specifications
  44
- Engine Specifications
  45
- Chassis Specifications
  51
- Electrical Specifications
  55
- Tightening Torques
  56
- Lubrication Points and Lubricant Types
  64
  - Engine
    64
  - Chassis
    66
- Lubrication System Chart and Diagrams
  68
  - Lubrication Diagrams
    68
- Cable Routing Diagram
  76
Periodic Checks and Adjustments

87
- Maintenance Intervals
  
  89
- Pre-Operation Inspection and Maintenance
  
  95
  - General Inspection and Maintenance
    95
- Engine
  
  96
  - Checking the Coolant Level
    96
  - Checking the Cooling System
    96
  - Changing the Coolant
    96
  - Checking the Radiator Cap
    97
  - Checking the Radiator Cap Opening Pressure
    97
  - Checking the Coolant Circulatory System for Leaks
    98
  - Adjusting the Clutch Lever Position
    98
  - Adjusting the Clutch Lever Free Play
    98
  - Adjusting the Throttle Grip Free Play
    99
  - Lubricating the Throttle Cable
    100
  - Cleaning the Air Filter Element
    100
  - Checking the Throttle Body Joint
    101
  - Checking the Breather Hoses
    101
  - Checking the Exhaust System
    101
  - Checking the Fuel Line
    102
  - Checking the Engine Oil Level
    102
  - Changing the Engine Oil
    103
  - Adjusting the Engine Idling Speed
    104
  - Adjusting the Valve Clearance
    105
- Chassis
  
  109
  - Bleeding the Brake System
    109
    
    Checking the Brake Hose
    110
    
    Adjusting the Front Brake
    110
    
    Adjusting the Rear Brake
    111
    
    Checking the Front Brake Pads
    111
    
    Checking the Rear Brake Pads
    113
    
    Checking the Rear Brake Pad Insulator
    114
    
    Checking the Brake Fluid Level
    114
    
    Adjusting the Drive Chain Slack
    115
    
    Checking the Front Fork Legs
    116
    
    Checking the Front Fork Protector Guide
    116
    
    Cleaning the Front Fork Oil Seal and Dust Seal
    116
    
    Air Bleeding from Front Fork
    116
    
    Adjusting the Front Fork Legs
    117
    
    Checking the Swingarm Operation
    118
    
    Checking the Rear Suspension
    118
    
    Adjusting the Rear Shock Absorber Assembly
    118
    
    Checking the Tires
    120
    
    Checking and Tightening the Spokes
    120
    
    Checking the Wheels
    121
    
    Checking the Wheel Bearings
    121
    
    Checking and Adjusting the Steering Head
    121
    
    Lubricating the Levers
    122
    
    Lubricating the Pedal
    122
- Electrical System
  
  123
  - Checking the Spark Plug
    123
  - Checking the Ignition Timing
    123
Chassis

125
- General Chassis
  
  127
  - Removing the Left Side Cover
    128
  - Removing the Seat
    128
  - Removing the Number Plate
    128
- Front Wheel
  
  130
  - Removing the Front Wheel
    130
  - Checking the Front Wheel
    130
  - Disassembling the Front Wheel
    131
  - Assembling the Front Wheel
    131
  - Installing the Front Wheel
    132
- Rear Wheel
  
  134
  - Removing the Rear Wheel
    134
  - Checking the Rear Wheel
    134
  - Disassembling the Rear Wheel
    134
  - Checking and Replacing the Rear Wheel Sprocket
    134
  - Assembling the Rear Wheel
    135
  - Installing the Rear Wheel
    135
- Front Brake
  
  137
- Rear Brake
  
  147
- Handlebar
  
  159
  - Removing the Handlebar
    159
  - Checking the Handlebar
    159
  - Installing the Handlebar
    159
- Front Fork
  
  163
  - Removing the Front Fork Legs
    165
  - Disassembling the Front Fork Legs
    165
  - Checking the Front Fork Legs
    166
  - Assembling the Front Fork Legs
    167
  - Installing the Front Fork Legs
    173
- Steering Head
  
  175
  - Removing the Lower Bracket
    176
  - Checking the Steering Head
    176
  - Installing the Steering Head
    176
- Rear Shock Absorber Assembly
  
  179
- Swingarm
  
  186
  - Removing the Swingarm
    187
  - Removing the Bearing
    187
  - Checking the Swingarm
    187
  - Installing the Swingarm
    188
- Chain Drive
  
  189
  - Removing the Drive Chain
    190
  - Checking the Drive Chain
    190
  - Checking the Drive Sprocket
    191
  - Checking the Rear Wheel Sprocket
    191
  - Installing the Drive Chain
    191
Engine

193
- Engine Removal
  
  196
  - Removing the Drive Sprocket
    201
  - Removing the Exhaust Pipe 2
    201
  - Removing the Silencer
    201
  - Changing the Silencer Fiber
    202
  - Checking the Silencer and Exhaust Pipe
    202
  - Removing the Engine
    202
  - Installing the Engine
    203
  - Installing the Brake Pedal
    204
  - Installing the Drive Sprocket
    204
  - Installing the Exhaust Pipe and Muffler
    205
- Camshaft
  
  206
  - Removing the Camshaft
    208
  - Checking the Camshaft
    209
  - Checking the Timing Chain and Camshaft Sprocket
    210
  - Checking the Timing Chain Tensioners
    210
  - Checking the Decompression System
    211
  - Installing the Camshafts
    211
- Cylinder Head
  
  214
- Valves and Valve Springs
  
  220
  - Removing the Valves
    220
  - Checking the Valves and Valve Guides
    221
  - Checking the Valve Seats
    222
  - Checking the Valve Springs
    224
  - Checking the Valve Lifters
    224
  - Installing the Valves
    225
- Cylinder and Piston
  
  228
  - Removing the Piston
    228
  - Checking the Cylinder and Piston
    228
  - Checking the Piston Rings
    229
  - Checking the Piston Pin
    230
  - Installing the Piston and Cylinder
    230
- Clutch
  
  233
  - Removing the Clutch
    235
  - Checking the Friction Plates
    235
  - Checking the Clutch Plates
    235
  - Checking the Clutch Springs
    235
  - Checking the Clutch Housing
    236
  - Checking the Clutch Boss
    236
  - Checking the Pressure Plate
    236
  - Checking the Push Lever Shaft
    236
  - Checking the Clutch Push Rods
    236
  - Checking the Primary Drive Gear
    236
  - Checking the Primary Driven Gear
    237
  - Installing the Oil Seal
    237
  - Installing the Right Crankcase Cover
    237
  - Installing the Clutch
    237
  - Installing the Kickstarter Lever
    240
- Kickstater
  
  242
- Shift Shaft
  
  244
  - Removing the Shift Guide and Shift Lever Assembly
    246
  - Removing the Segment
    246
  - Checking the Shift Shaft
    246
  - Checking the Shift Guide and Shift Lever Assembly
    246
  - Checking the Stopper Lever
    246
  - Installing the Stopper Lever
    247
  - Installing the Segment
    247
  - Installing the Shift Guide and Shift Lever Assembly
    247
  - Installing the Shift Shaft
    248
  - Installing the Shift Pedal
    248
- Oil Pump and Balancer Gear
  
  250
- Ac Magneto
  
  254
  - Removing the Ac Magneto
    255
  - Checking the Ac Magneto
    255
  - Checking the Woodruff Key
    255
  - Installing the Ac Magneto
    255
- Crankcase
  
  257
- Crankshaft Assembly and Balancer Shaft
  
  262
- Transmission
  
  266
  - Removing the Transmission
    266
  - Checking the Shift Forks
    266
  - Checking the Shift Drum Assembly
    267
  - Checking the Transmission
    267
  - Installing the Transmission
    267
  - Cooling System
    271
Fuel System

279
- Fuel Tank
  
  280
  - Checking the Fuel Pump Body
    281
  - Installing the Fuel Pump
    281
  - Removing the Fuel Pump
    281
  - Removing the Fuel Tank
    281
  - Checking the Fuel Pressure
    282
  - Installing the Fuel Tank
    282
  - Checking and Replacing the Protector
    283
  - Checking the Damper
    283
- Throttle Body
  
  284
  - Checking the Injector
    287
  - Checking the Throttle Body
    287
  - Checking the Throttle Body Joint
    287
  - Adjusting the Throttle Position Sensor
    288
Electrical System

289
- Ignition System
  
  292
  - Circuit Diagram
    292
  - Troubleshooting
    294
- Charging System
  
  296
  - Circuit Diagram
    296
  - Troubleshooting
    298
- Fuel Injection System
  
  300
  - Circuit Diagram
    300
  - Yamaha Diagnostic Tool
    302
  - Troubleshooting Details
    303
- Fuel Pump System
  
  322
  - Circuit Diagram
    322
  - Troubleshooting
    324
- Electrical Components
  
  326
  - Checking the Switches
    328
  - Checking the Ignition Spark Gap
    331
  - Checking the Spark Plug Cap
    331
  - Checking the Ignition Coil
    331
  - Checking the Crankshaft Position Sensor
    332
  - Checking the Ecu
    333
  - Checking the Stator Coil
    333
  - Checking the Rectifier/Regulator
    333
  - Checking the Coolant Temperature Sensor
    334
  - Checking the Throttle Position Sensor
    334
  - Checking the Throttle Position Sensor Input Voltage
    335
  - Checking the Intake Air Pressure Sensor
    336
  - Checking the Intake Air Temperature Sensor
    336
  - Checking the Neutral Switch
    336
  - Checking the Fuel Injector
    337
Troubleshooting

339
- General Information
  339
- Troubleshooting
  
  340
  - General Information
    340
  - Incorrect Engine Idling Speed
    340
  - Starting Failures
    340
  - Faulty Clutch
    341
  - Faulty Gear Shifting
    341
  - Jumps out of Gear
    341
  - Overheating
    341
  - Poor Medium-And-High-Speed Performance
    341
  - Shift Pedal Does Not Move
    341
  - Faulty Front Fork Legs
    342
  - Overcooling
    342
  - Poor Braking Performance
    342
  - Unstable Handling
    342
- List of Self-Diagnostic and Fail-Safe Actions
  
  343
Tuning

347
- Chassis
  348
- Drive and Rear Wheel Sprockets Setting Parts
  348
- Selection of the Secondary Reduction Ratio (Sprocket)
  348
- Change in Amount and Characteristics of Fork Oil
  349
- Front Fork Setting
  349
- Tire Pressure
  349
- Choosing Set Length
  350
- Front Fork Setting Parts
  350
- Rear Suspension Setting
  350
- Setting of Spring after Replacement
  350
- Setting of Spring after Replacement
  351
- Rear Shock Absorber Setting Parts
  352
- Suspension Setting (Front Fork)
  353
- Suspension Setting (Rear Shock Absorber)
  354
  - Wiring Diagram
    356

Advertisement

Advertisement

Related Products

Yamaha Categories

Motorcycle Musical Instrument Electronic Keyboard Receiver Amplifier

More Yamaha Manuals