Yamaha YZ450FL 2020 Manuals

Manuals and User Guides for Yamaha YZ450FL 2020. We have 1 Yamaha YZ450FL 2020 manual available for free PDF download: Owner's Service Manual

Yamaha YZ450FL 2020 Owner's Service Manual

Yamaha YZ450FL 2020 Owner's Service Manual (370 pages)

Brand: Yamaha | Category: Motorcycle | Size: 26 MB

Table of Contents

General Information

13
- General Information
  11
  - Table of Contents
    13
- Safety Information
  15
- For Safety, be Sure to Obey the Following
  15
- Location of Important Labels
  18
- Description
  21
- Identification
  22
- Vehicle Identification Number
  22
- Engine Serial Number
  22
- Power Tuner
  23
- Fuel Hose Joint Cover
  23
- Handlebar Protector
  23
- Nipple Wrench
  23
- Sidestand
  23
- Included Parts
  23
- Important Information
  25
- Preparation for Removal and Disassembly
  25
- Replacement Parts
  25
- Gaskets, Oil Seals and O-Rings
  25
- Lock Washers/Plates and Cotter Pins
  26
- Bearings and Oil Seals
  26
- Circlips
  26
- Basic Service Information
  27
- Electrical System
  27
- Special Tools
  31
- Instrument and Control Functions
  37
- Engine Stop Switch
  37
- Start Switch
  37
- Launch Control Switch
  37
- Mode Switch
  37
- Starter Knob
  38
- Rear Brake Pedal
  38
- Front Brake Lever
  38
- Shift Pedal
  38
- Fuel Tank Cap
  39
- Starting and Break-In
  40
- Fuel
  40
- Starting a Cold Engine
  40
- Starting a Warm Engine
  41
- Break-In Procedures
  41
- Engine Starting Precaution
  41
- Air Filter Maintenance
  42
- Major Maintenance
  42
- Maintenance after Break-In
  42
- Torque-Check Points
  43
- Motorcycle Care and Storage
  45
- Care
  45
- Storage
  46
Specifications

49
- General Specifications
  50
- Specifications
  50
- Engine Specifications
  51
- Chassis Specifications
  55
- Electrical Specifications
  58
- General Tightening Torque Specifications
  59
- Tightening Torques
  59
- Engine Tightening Torques
  60
- Chassis Tightening Torques
  63
- Cable Routing Diagram
  66
Periodic Checks and Adjustments

79
- Maintenance Intervals
  81
- General Inspection and Maintenance
  85
- Pre-Operation Inspection and Maintenance
  85
- Adjusting the Valve Clearance
  86
- Engine
  86
- Valve Clearance Shim Chart
  89
- Checking the Engine Idling Speed
  91
- Checking the Throttle Grip
  91
- Checking the Spark Plug
  92
- Changing the Engine Oil
  93
- Checking the Engine Oil Level
  93
- Adjusting the Clutch Lever Free Play
  95
- Adjusting the Clutch Lever Position
  95
- Cleaning the Air Filter Element
  95
- Checking the Fuel Line
  97
- Checking the Throttle Body Joint
  97
- Checking the Cylinder Head Breather Hose
  98
- Checking the Exhaust System
  98
- Checking the Coolant Level
  100
- Checking the Cooling System
  100
- Changing the Coolant
  101
- Adjusting the Front Disc Brake
  102
- Adjusting the Rear Disc Brake
  102
- Chassis
  102
- Checking the Brake Fluid Level
  103
- Checking the Front Brake Hose
  103
- Checking the Front Brake Pads
  103
- Checking the Rear Brake Pads
  103
- Bleeding the Hydraulic Brake System
  104
- Checking the Brake Operation
  104
- Checking the Rear Brake Hose
  104
- Drive Chain Slack
  105
- Checking and Adjusting the Steering Head
  106
- Checking the Front Fork Legs
  107
- Lubricating the Steering Head
  107
- Adjusting the Front Fork Legs
  108
- Adjusting the Rear Shock Absorber Assembly
  109
- Checking the Rear Shock Absorber Assembly
  109
- Checking and Tightening the Spokes
  112
- Checking the Connecting Arm and Relay Arm
  112
- Checking the Swingarm Operation
  112
- Checking the Tires
  112
- Lubricating the Swingarm Pivot
  112
- Checking the Wheels
  113
Chassis

117
- General Chassis
  119
- Installing the Air Scoop
  121
- Removing the Number Plate
  121
- Removing the Seat
  121
- Installing the Side Cover
  122
- Removing the Side Cover
  122
- Front Wheel
  123
- Checking the Front Wheel
  124
- Disassembling the Front Wheel
  124
- Removing the Front Wheel
  124
- Assembling the Front Wheel
  125
- Installing the Front Wheel (Disc Brake)
  126
- Rear Wheel
  127
- Checking and Replacing the Rear Wheel Sprocket
  128
- Checking the Rear Wheel
  128
- Disassembling the Rear Wheel
  128
- Removing the Rear Wheel
  128
- Assembling the Rear Wheel
  129
- Installing the Rear Wheel (Disc Brake)
  129
- Front Brake
  131
- Checking the Front Brake Disc
  135
- Introduction
  135
- Replacing the Front Brake Pads
  136
- Disassembling the Front Brake Caliper
  137
- Removing the Front Brake Caliper
  137
- Assembling the Front Brake Caliper
  138
- Checking the Front Brake Caliper
  138
- Installing the Front Brake Caliper
  138
- Assembling the Front Brake Master Cylinder
  139
- Checking the Front Brake Master Cylinder
  139
- Removing the Front Brake Master Cylinder
  139
- Installing the Front Brake Master Cylinder
  140
- Rear Brake
  142
- Checking the Rear Brake Disc
  146
- Introduction
  146
- Replacing the Rear Brake Pads
  146
- Checking the Rear Brake Caliper
  148
- Disassembling the Rear Brake Caliper
  148
- Removing the Rear Brake Caliper
  148
- Assembling the Rear Brake Caliper
  149
- Installing the Rear Brake Caliper
  149
- Assembling the Rear Brake Master Cylinder
  150
- Checking the Rear Brake Master Cylinder
  150
- Removing the Rear Brake Master Cylinder
  150
- Installing the Rear Brake Master Cylinder
  151
- Handlebar
  153
- Checking the Handlebar
  155
- Installing the Handlebar
  155
- Removing the Handlebar
  155
- Front Fork
  160
- Disassembling the Front Fork Legs
  162
- Removing the Front Fork Legs
  162
- Checking the Front Fork Legs
  163
- Assembling the Front Fork Legs
  164
- Installing the Front Fork Legs
  171
- Steering Head
  173
- Checking the Steering Head
  174
- Installing the Steering Head
  174
- Removing the Lower Bracket
  174
- Rear Shock Absorber Assembly
  177
- Checking the Rear Shock Absorber Assembly
  180
- Disposing of a Rear Shock Absorber
  180
- Handling the Rear Shock Absorber
  180
- Removing the Rear Shock Absorber Assembly
  180
- Checking the Connecting Arm and Relay Arm
  181
- Installing the Rear Shock Absorber Assembly
  181
- Installing the Relay Arm
  181
- Swingarm
  183
- Checking the Swingarm
  184
- Installing the Swingarm
  184
- Removing the Swingarm
  184
- Chain Drive
  186
- Checking the Drive Chain
  187
- Removing the Drive Chain
  187
- Checking the Drive Sprocket
  188
- Checking the Rear Wheel Sprocket
  188
- Installing the Drive Chain
  188
Engine

189
- Engine Oil Lubrication Chart
  191
- Lubrication System Chart and Diagrams
  191
- Lubrication Diagrams
  192
- Engine Removal
  196
- Installing the Engine
  200
- Removing the Engine
  200
- Installing the Exhaust Pipe and Muffler
  201
- Camshaft
  203
- Removing the Camshaft
  205
- Checking the Camshaft
  206
- Checking the Decompression System
  207
- Checking the Timing Chain and Camshaft Sprocket
  207
- Checking the Timing Chain Tensioners
  207
- Installing the Camshafts
  208
- Cylinder Head
  212
- Checking the Cylinder Head
  213
- Checking the Timing Chain Guide (Intake Side)
  213
- Removing the Cylinder Head
  213
- Installing the Cylinder Head
  214
- Removing the Valves
  217
- Valves and Valve Springs
  217
- Checking the Valves and Valve Guides
  218
- Checking the Valve Seats
  219
- Checking the Valve Springs
  220
- Checking the Valve Lifters
  221
- Installing the Valves
  221
- Cylinder and Piston
  223
- Checking the Cylinder and Piston
  224
- Removing the Piston
  224
- Checking the Piston Rings
  225
- Checking the Piston Pin
  226
- Installing the Piston and Cylinder
  226
- Generator
  228
- Checking the Generator
  229
- Checking the Woodruff Key
  229
- Installing the Generator
  229
- Removing the Generator
  229
- Starter Clutch
  231
- Checking the Starter Clutch
  232
- Assembling the Starter Motor
  235
- Checking the Starter Motor
  235
- Electric Starter
  235
- Clutch
  237
- Checking the Clutch Plates
  240
- Checking the Clutch Springs
  240
- Checking the Friction Plates
  240
- Removing the Clutch
  240
- Checking the Clutch Boss
  241
- Checking the Clutch Housing
  241
- Checking the Pressure Plate
  241
- Checking the Primary Drive Gear
  241
- Checking the Push Lever Shaft
  241
- Checking the Push Rods
  241
- Checking the Primary Driven Gear
  242
- Installing the Clutch
  242
- Checking the Shift Shaft
  246
- Checking the Stopper Lever
  246
- Installing the Shift
  246
- Removing the Segment
  246
- Shift Shaft
  246
- Oil Pump
  250
- Checking the Oil Pump
  251
- Removing the Oil Pump
  251
- Assembling the Oil Pump
  252
- Installing the Oil Pump
  252
- Crankcase
  255
- Checking the Crankcase
  257
- Checking the Timing Chain Guide (Exhaust Side)
  257
- Disassembling the Crankcase
  257
- Assembling the Crankcase
  258
- Crankshaft and Balancer Shaft
  259
- Checking the Crankshaft
  260
- Removing the Crankshaft
  260
- Installing the Crankshaft
  261
- Transmission
  262
- Checking the Shift Drum Assembly
  263
- Checking the Shift Forks
  263
- Removing the Transmission
  263
- Checking the Transmission
  264
- Installing the Transmission
  264
Cooling System

267
- Cooling System
  268
- Cooling System Diagrams
  268
- Radiator
  269
- Checking the Radiator
  271
- Installing the Radiator
  271
- Assembling the Water Pump
  274
- Checking the Water Pump
  274
- Disassembling the Water Pump
  274
- Water Pump
  274
Fuel System

277
- Fuel Tank
  278
- Checking the Fuel Pump Body
  279
- Checking the Fuel Pump Operation
  279
- Installing the Fuel Pump
  279
- Removing the Fuel Pump
  279
- Removing the Fuel Tank
  279
- Installing the Fuel Tank
  280
- Throttle Body
  281
- Checking the Fuel Pressure
  284
- Checking the Injector
  284
- Checking the Throttle Body
  284
- Adjusting the Throttle Position Sensor
  285
Electrical System

287
- Circuit Diagram
  288
- Ignition System
  288
- Troubleshooting
  290
- Circuit Diagram
  294
- Electric Starting System
  294
- Troubleshooting
  296
- Charging System
  298
- Circuit Diagram
  298
- Troubleshooting
  300
- Circuit Diagram
  302
- Fuel Injection System
  302
- Connecting the Yamaha Diagnostic Tool
  304
- Yamaha Diagnostic Tool
  304
- Troubleshooting Details (Fault Code)
  306
- Circuit Diagram
  324
- Fuel Pump System
  324
- Troubleshooting
  326
- Electrical Components
  327
- Checking the Switches
  328
- Checking and Charging the Battery
  330
- Checking the Fuses
  330
- Checking the Relay Unit (Diode)
  332
- Checking the Relays
  332
- Checking the Ignition Spark Gap
  333
- Checking the Spark Plug Cap
  333
- Checking the Crankshaft Position Sensor
  334
- Checking the Ignition Coil
  334
- Checking the Lean Angle Sensor
  335
- Checking the Rectifier/Regulator
  335
- Checking the Starter Motor Operation
  335
- Checking the Stator Coil
  335
- Checking the Coolant Temperature Sensor
  336
- Checking the Intake Air Temperature Sensor
  337
- Checking the Throttle Position Sensor Input Voltage
  337
- Checking the Gear Position Switch
  338
- Checking the Injector
  338
Troubleshooting

339
Tuning

355
- Chassis
  356
- Drive and Rear Wheel Sprockets Setting Parts
  356
- Selection of the Secondary Reduction Ratio (Sprocket)
  356
- Tire Pressure
  356
- Change in Amount and Characteristics of Fork Oil
  357
- Front Fork Setting
  357
- Setting of Spring after Replacement
  357
- Choosing Set Length
  358
- Front Fork Setting Parts
  358
- Rear Suspension Setting
  358
- Rear Shock Absorber Setting Parts
  359
- Setting of Spring after Replacement
  359
- Suspension Setting (Front Fork)
  361
- Suspension Setting (Rear Shock Absorber)
  362

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