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
Important Manual Information6................................................................................................................................................................
Safety Information7................................................................................................................................................................
How To Use This Manual8................................................................................................................................................................
Table Of Contents11................................................................................................................................................................
General Information13................................................................................................................................................................
Location Of Important Labels15................................................................................................................................................................
Description18................................................................................................................................................................
Identification19................................................................................................................................................................
Vehicle Identification Number19................................................................................................................................................................
Engine Serial Number19................................................................................................................................................................
Model Label19................................................................................................................................................................
Features20................................................................................................................................................................
Outline Of The Fi System20................................................................................................................................................................
Fi System21................................................................................................................................................................
Included Parts22................................................................................................................................................................
Sidestand22................................................................................................................................................................
Spark Plug Wrench22................................................................................................................................................................
Nipple Wrench22................................................................................................................................................................
Handlebar Protector22................................................................................................................................................................
Fuel Hose Joint Cover22................................................................................................................................................................
Coupler For Connecting Optional Part22................................................................................................................................................................
Important Information24................................................................................................................................................................
Preparation For Removal And Disassembly24................................................................................................................................................................
Replacement Parts24................................................................................................................................................................
Gaskets, Oil Seals And O-rings25................................................................................................................................................................
Lock Washers/plates And Cotter Pins25................................................................................................................................................................
Bearings And Oil Seals25................................................................................................................................................................
Circlips25................................................................................................................................................................
Basic Service Information26................................................................................................................................................................
Electrical System26................................................................................................................................................................
Special Tools29................................................................................................................................................................
Control Functions34................................................................................................................................................................
Engine Stop Switch34................................................................................................................................................................
Clutch Lever34................................................................................................................................................................
Shift Pedal34................................................................................................................................................................
Kickstarter Lever34................................................................................................................................................................
Throttle Grip34................................................................................................................................................................
Front Brake Lever34................................................................................................................................................................
Rear Brake Pedal35................................................................................................................................................................
Starter Knob/idle Screw35................................................................................................................................................................
Fuel Tank Cap35................................................................................................................................................................
Starting And Break-in36................................................................................................................................................................
Fuel36................................................................................................................................................................
Starting A Cold Engine36................................................................................................................................................................
Starting A Warm Engine37................................................................................................................................................................
Break-in Procedures37................................................................................................................................................................
Maintenance After Break-in38................................................................................................................................................................
Major Maintenance38................................................................................................................................................................
Torque-check Points39................................................................................................................................................................
Cleaning And Storage41................................................................................................................................................................
Cleaning41................................................................................................................................................................
Storage41................................................................................................................................................................
Specifications43................................................................................................................................................................
General Specifications44................................................................................................................................................................
Engine Specifications45................................................................................................................................................................
Chassis Specifications51................................................................................................................................................................
Electrical Specifications55................................................................................................................................................................
Tightening Torques56................................................................................................................................................................
General Tightening Torque Specifications56................................................................................................................................................................
Engine Tightening Torques57................................................................................................................................................................
Chassis Tightening Torques61................................................................................................................................................................
Lubrication Points And Lubricant Types64................................................................................................................................................................
Engine64................................................................................................................................................................
Chassis66................................................................................................................................................................
Lubrication System Chart And Diagrams68................................................................................................................................................................
Lubrication Diagrams68................................................................................................................................................................
Cable Routing Diagram76................................................................................................................................................................
Periodic Checks And Adjustments87................................................................................................................................................................
Maintenance Intervals89................................................................................................................................................................
Pre-operation Inspection And Maintenance95................................................................................................................................................................
General Inspection And Maintenance95................................................................................................................................................................
Checking The Coolant Level96................................................................................................................................................................
Checking The Cooling System96................................................................................................................................................................
Changing The Coolant96................................................................................................................................................................
Checking The Radiator Cap97................................................................................................................................................................
Checking The Radiator Cap Opening Pressure97................................................................................................................................................................
Checking The Coolant Circulatory System For Leaks98................................................................................................................................................................
Adjusting The Clutch Lever Position98................................................................................................................................................................
Adjusting The Clutch Lever Free Play98................................................................................................................................................................
Adjusting The Throttle Grip Free Play99................................................................................................................................................................
Lubricating The Throttle Cable100................................................................................................................................................................
Cleaning The Air Filter Element100................................................................................................................................................................
Checking The Throttle Body Joint101................................................................................................................................................................
Checking The Breather Hoses101................................................................................................................................................................
Checking The Exhaust System101................................................................................................................................................................
Checking The Fuel Line102................................................................................................................................................................
Checking The Engine Oil Level102................................................................................................................................................................
Changing The Engine Oil103................................................................................................................................................................
Adjusting The Engine Idling Speed104................................................................................................................................................................
Adjusting The Valve Clearance105................................................................................................................................................................
Bleeding The Brake System109................................................................................................................................................................
Checking The Brake Hose110................................................................................................................................................................
Adjusting The Front Brake110................................................................................................................................................................
Adjusting The Rear Brake111................................................................................................................................................................
Checking The Front Brake Pads111................................................................................................................................................................
Checking The Rear Brake Pads113................................................................................................................................................................
Checking The Rear Brake Pad Insulator114................................................................................................................................................................
Checking The Brake Fluid Level114................................................................................................................................................................
Adjusting The Drive Chain Slack115................................................................................................................................................................
Checking The Front Fork Legs116................................................................................................................................................................
Checking The Front Fork Protector Guide116................................................................................................................................................................
Cleaning The Front Fork Oil Seal And Dust Seal116................................................................................................................................................................
Air Bleeding From Front Fork116................................................................................................................................................................
Adjusting The Front Fork Legs117................................................................................................................................................................
Checking The Swingarm Operation118................................................................................................................................................................
Checking The Rear Suspension118................................................................................................................................................................
Adjusting The Rear Shock Absorber Assembly118................................................................................................................................................................
Checking The Tires120................................................................................................................................................................
Checking And Tightening The Spokes120................................................................................................................................................................
Checking The Wheels121................................................................................................................................................................
Checking The Wheel Bearings121................................................................................................................................................................
Checking And Adjusting The Steering Head121................................................................................................................................................................
Lubricating The Levers122................................................................................................................................................................
Lubricating The Pedal122................................................................................................................................................................
Checking The Spark Plug123................................................................................................................................................................
Checking The Ignition Timing123................................................................................................................................................................
General Chassis127................................................................................................................................................................
Removing The Left Side Cover128................................................................................................................................................................
Removing The Seat128................................................................................................................................................................
Removing The Number Plate128................................................................................................................................................................
Front Wheel130................................................................................................................................................................
Removing The Front Wheel130................................................................................................................................................................
Checking The Front Wheel130................................................................................................................................................................
Disassembling The Front Wheel131................................................................................................................................................................
Assembling The Front Wheel131................................................................................................................................................................
Installing The Front Wheel132................................................................................................................................................................
Rear Wheel134................................................................................................................................................................
Removing The Rear Wheel134................................................................................................................................................................
Checking The Rear Wheel134................................................................................................................................................................
Disassembling The Rear Wheel134................................................................................................................................................................
Checking And Replacing The Rear Wheel Sprocket134................................................................................................................................................................
Assembling The Rear Wheel135................................................................................................................................................................
Installing The Rear Wheel135................................................................................................................................................................
Front Brake137................................................................................................................................................................
Introduction141................................................................................................................................................................
Checking The Front Brake Disc141................................................................................................................................................................
Removing The Front Brake Caliper141................................................................................................................................................................
Disassembling The Front Brake Caliper141................................................................................................................................................................
Checking The Front Brake Caliper142................................................................................................................................................................
Assembling The Front Brake Caliper142................................................................................................................................................................
Installing The Brake Caliper Piston142................................................................................................................................................................
Installing The Front Brake Caliper143................................................................................................................................................................
Removing The Front Brake Master Cylinder144................................................................................................................................................................
Checking The Front Brake Master Cylinder144................................................................................................................................................................
Assembling The Front Brake Master Cylinder144................................................................................................................................................................
Installing The Front Brake Master Cylinder145................................................................................................................................................................
Rear Brake147................................................................................................................................................................
Checking The Rear Brake Disc151................................................................................................................................................................
Removing The Rear Brake Caliper152................................................................................................................................................................
Disassembling The Rear Brake Caliper152................................................................................................................................................................
Checking The Rear Brake Caliper152................................................................................................................................................................
Assembling The Rear Brake Caliper152................................................................................................................................................................
Installing The Rear Brake Caliper153................................................................................................................................................................
Removing The Rear Brake Master Cylinder154................................................................................................................................................................
Checking The Rear Brake Master Cylinder154................................................................................................................................................................
Assembling The Rear Brake Master Cylinder155................................................................................................................................................................
Installing The Rear Brake Master Cylinder155................................................................................................................................................................
Handlebar159................................................................................................................................................................
Removing The Handlebar159................................................................................................................................................................
Checking The Handlebar159................................................................................................................................................................
Installing The Handlebar159................................................................................................................................................................
Front Fork163................................................................................................................................................................
Removing The Front Fork Legs165................................................................................................................................................................
Disassembling The Front Fork Legs165................................................................................................................................................................
Assembling The Front Fork Legs167................................................................................................................................................................
Installing The Front Fork Legs173................................................................................................................................................................
Steering Head175................................................................................................................................................................
Removing The Lower Bracket176................................................................................................................................................................
Checking The Steering Head176................................................................................................................................................................
Installing The Steering Head176................................................................................................................................................................
Rear Shock Absorber Assembly179................................................................................................................................................................
Handling The Rear Shock Absorber182................................................................................................................................................................
Disposing Of A Rear Shock Absorber182................................................................................................................................................................
Removing The Rear Shock Absorber Assembly182................................................................................................................................................................
Removing The Bearing182................................................................................................................................................................
Checking The Rear Shock Absorber Assembly183................................................................................................................................................................
Checking The Connecting Arm And Relay Arm183................................................................................................................................................................
Installing The Relay Arm183................................................................................................................................................................
Installing The Rear Shock Absorber Assembly184................................................................................................................................................................
Swingarm186................................................................................................................................................................
Removing The Swingarm187................................................................................................................................................................
Checking The Swingarm187................................................................................................................................................................
Installing The Swingarm188................................................................................................................................................................
Chain Drive189................................................................................................................................................................
Removing The Drive Chain190................................................................................................................................................................
Checking The Drive Chain190................................................................................................................................................................
Checking The Drive Sprocket191................................................................................................................................................................
Checking The Rear Wheel Sprocket191................................................................................................................................................................
Installing The Drive Chain191................................................................................................................................................................
Engine Removal196................................................................................................................................................................
Removing The Silencer201................................................................................................................................................................
Removing The Exhaust Pipe 2201................................................................................................................................................................
Removing The Drive Sprocket201................................................................................................................................................................
Removing The Engine202................................................................................................................................................................
Checking The Silencer And Exhaust Pipe202................................................................................................................................................................
Changing The Silencer Fiber202................................................................................................................................................................
Installing The Engine203................................................................................................................................................................
Installing The Brake Pedal204................................................................................................................................................................
Installing The Drive Sprocket204................................................................................................................................................................
Installing The Exhaust Pipe And Muffler205................................................................................................................................................................
Camshaft206................................................................................................................................................................
Removing The Camshaft208................................................................................................................................................................
Checking The Camshaft209................................................................................................................................................................
Checking The Timing Chain And Camshaft Sprocket210................................................................................................................................................................
Checking The Timing Chain Tensioners210................................................................................................................................................................
Checking The Decompression System211................................................................................................................................................................
Installing The Camshafts211................................................................................................................................................................
Cylinder Head214................................................................................................................................................................
Removing The Cylinder Head216................................................................................................................................................................
Checking The Timing Chain Guide (intake Side)216................................................................................................................................................................
Checking The Cylinder Head216................................................................................................................................................................
Installing The Cylinder Head217................................................................................................................................................................
Valves And Valve Springs220................................................................................................................................................................
Removing The Valves220................................................................................................................................................................
Checking The Valves And Valve Guides221................................................................................................................................................................
Checking The Valve Seats222................................................................................................................................................................
Checking The Valve Springs224................................................................................................................................................................
Checking The Valve Lifters224................................................................................................................................................................
Installing The Valves225................................................................................................................................................................
Cylinder And Piston228................................................................................................................................................................
Removing The Piston228................................................................................................................................................................
Checking The Cylinder And Piston228................................................................................................................................................................
Checking The Piston Rings229................................................................................................................................................................
Checking The Piston Pin230................................................................................................................................................................
Installing The Piston And Cylinder230................................................................................................................................................................
Clutch233................................................................................................................................................................
Removing The Clutch235................................................................................................................................................................
Checking The Friction Plates235................................................................................................................................................................
Checking The Clutch Plates235................................................................................................................................................................
Checking The Clutch Springs235................................................................................................................................................................
Checking The Clutch Housing236................................................................................................................................................................
Checking The Clutch Boss236................................................................................................................................................................
Checking The Pressure Plate236................................................................................................................................................................
Checking The Push Lever Shaft236................................................................................................................................................................
Checking The Clutch Push Rods236................................................................................................................................................................
Checking The Primary Drive Gear236................................................................................................................................................................
Checking The Primary Driven Gear237................................................................................................................................................................
Installing The Oil Seal237................................................................................................................................................................
Installing The Right Crankcase Cover237................................................................................................................................................................
Installing The Clutch237................................................................................................................................................................
Installing The Kickstarter Lever240................................................................................................................................................................
Kickstater242................................................................................................................................................................
Removing The Kick Shaft Assembly242................................................................................................................................................................
Checking The Kick Shaft And Ratchet Wheel242................................................................................................................................................................
Checking The Kick Gear, Kick Idle Gear And Ratchet Wheel242................................................................................................................................................................
Installing The Kick Shaft Assembly242................................................................................................................................................................
Installing The Kick Idle Gear243................................................................................................................................................................
Shift Shaft244................................................................................................................................................................
Removing The Shift Guide And Shift Lever Assembly246................................................................................................................................................................
Removing The Segment246................................................................................................................................................................
Checking The Shift Shaft246................................................................................................................................................................
Checking The Shift Guide And Shift Lever Assembly246................................................................................................................................................................
Checking The Stopper Lever246................................................................................................................................................................
Installing The Stopper Lever247................................................................................................................................................................
Installing The Segment247................................................................................................................................................................
Installing The Shift Guide And Shift Lever Assembly247................................................................................................................................................................
Installing The Shift Shaft248................................................................................................................................................................
Installing The Shift Pedal248................................................................................................................................................................
Oil Pump And Balancer Gear250................................................................................................................................................................
Removing The Balancer251................................................................................................................................................................
Checking The Primary Drive Gear, Balancer Shaft Drive Gear, And Balancer Weight Gear251................................................................................................................................................................
Checking The Balancer251................................................................................................................................................................
Checking The Oil Pump251................................................................................................................................................................
Assembling The Oil Pump252................................................................................................................................................................
Installing The Oil Pump And Balancer Gear252................................................................................................................................................................
Ac Magneto254................................................................................................................................................................
Removing The Ac Magneto255................................................................................................................................................................
Checking The Ac Magneto255................................................................................................................................................................
Checking The Woodruff Key255................................................................................................................................................................
Installing The Ac Magneto255................................................................................................................................................................
Crankcase257................................................................................................................................................................
Disassembling The Crankcase260................................................................................................................................................................
Removing The Crankcase Bearing260................................................................................................................................................................
Checking The Timing Chain, Timing Chain Guide, Oil Strainer260................................................................................................................................................................
Checking The Crankcase260................................................................................................................................................................
Assembling The Crankcase261................................................................................................................................................................
Crankshaft Assembly And Balancer Shaft262................................................................................................................................................................
Removing The Balancer Shaft263................................................................................................................................................................
Removing The Crankshaft Assembly263................................................................................................................................................................
Checking The Crankshaft Assembly263................................................................................................................................................................
Installing The Crankshaft Assembly264................................................................................................................................................................
Transmission266................................................................................................................................................................
Removing The Transmission266................................................................................................................................................................
Checking The Shift Forks266................................................................................................................................................................
Checking The Shift Drum Assembly267................................................................................................................................................................
Checking The Transmission267................................................................................................................................................................
Installing The Transmission267................................................................................................................................................................
Cooling System271................................................................................................................................................................
Fuel System279................................................................................................................................................................
Fuel Tank280................................................................................................................................................................
Removing The Fuel Tank281................................................................................................................................................................
Removing The Fuel Pump281................................................................................................................................................................
Checking The Fuel Pump Body281................................................................................................................................................................
Installing The Fuel Pump281................................................................................................................................................................
Installing The Fuel Tank282................................................................................................................................................................
Checking The Fuel Pressure282................................................................................................................................................................
Checking The Damper283................................................................................................................................................................
Checking And Replacing The Protector283................................................................................................................................................................
Throttle Body284................................................................................................................................................................
Checking The Injector287................................................................................................................................................................
Checking The Throttle Body287................................................................................................................................................................
Adjusting The Throttle Position Sensor288................................................................................................................................................................
Ignition System292................................................................................................................................................................
Circuit Diagram292................................................................................................................................................................
Troubleshooting294................................................................................................................................................................
Charging System296................................................................................................................................................................
Fuel Injection System300................................................................................................................................................................
Yamaha Diagnostic Tool302................................................................................................................................................................
Troubleshooting Details303................................................................................................................................................................
Fuel Pump System322................................................................................................................................................................
Electrical Components326................................................................................................................................................................
Checking The Switches328................................................................................................................................................................
Checking The Ignition Spark Gap331................................................................................................................................................................
Checking The Spark Plug Cap331................................................................................................................................................................
Checking The Ignition Coil331................................................................................................................................................................
Checking The Crankshaft Position Sensor332................................................................................................................................................................
Checking The Ecu333................................................................................................................................................................
Checking The Stator Coil333................................................................................................................................................................
Checking The Rectifier/regulator333................................................................................................................................................................
Checking The Coolant Temperature Sensor334................................................................................................................................................................
Checking The Throttle Position Sensor334................................................................................................................................................................
Checking The Throttle Position Sensor Input Voltage335................................................................................................................................................................
Checking The Intake Air Pressure Sensor336................................................................................................................................................................
Checking The Intake Air Temperature Sensor336................................................................................................................................................................
Checking The Neutral Switch336................................................................................................................................................................
Checking The Fuel Injector337................................................................................................................................................................
Starting Failures340................................................................................................................................................................
Incorrect Engine Idling Speed340................................................................................................................................................................
Poor Medium-and-high-speed Performance341................................................................................................................................................................
Faulty Gear Shifting341................................................................................................................................................................
Shift Pedal Does Not Move341................................................................................................................................................................
Jumps Out Of Gear341................................................................................................................................................................
Faulty Clutch341................................................................................................................................................................
Overheating341................................................................................................................................................................
Overcooling342................................................................................................................................................................
Poor Braking Performance342................................................................................................................................................................
Faulty Front Fork Legs342................................................................................................................................................................
Unstable Handling342................................................................................................................................................................
List Of Self-diagnostic And Fail-safe Actions343................................................................................................................................................................
Tuning347................................................................................................................................................................
Selection Of The Secondary Reduction Ratio (sprocket)348................................................................................................................................................................
Drive And Rear Wheel Sprockets Setting Parts348................................................................................................................................................................
Tire Pressure349................................................................................................................................................................
Front Fork Setting349................................................................................................................................................................
Change In Amount And Characteristics Of Fork Oil349................................................................................................................................................................
Setting Of Spring After Replacement350................................................................................................................................................................
Front Fork Setting Parts350................................................................................................................................................................
Rear Suspension Setting350................................................................................................................................................................
Choosing Set Length350................................................................................................................................................................
Rear Shock Absorber Setting Parts352................................................................................................................................................................
Suspension Setting (front Fork)353................................................................................................................................................................
Suspension Setting (rear Shock Absorber)354................................................................................................................................................................
Wiring Diagram356................................................................................................................................................................

Advertisement

Share and save

Advertisement