User Manuals: Yamaha YZ450FP 2023 Motocross Motorcycle

Manuals and User Guides for Yamaha YZ450FP 2023 Motocross Motorcycle. We have 2 Yamaha YZ450FP 2023 Motocross Motorcycle manuals available for free PDF download: Owner's Service Manual, Owner's Manual

Yamaha YZ450FP 2023 Owner's Service Manual (388 pages)

Brand: Yamaha | Category: Motorcycle | Size: 26.84 MB

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

77
- Maintenance Intervals
  80
- General Inspection and Maintenance
  84
- Pre-Operation Inspection and Maintenance
  84
- Adjusting the Valve Clearance
  85
- Engine
  85
- Valve Clearance Shim Chart
  88
- Checking the Engine Idling Speed
  90
- Checking the Throttle Grip
  90
- Checking the Engine Oil Level
  91
- Checking the Spark Plug
  91
- Changing the Engine Oil
  92
- Adjusting the Clutch Lever Free Play
  93
- Adjusting the Clutch Lever Position
  94
- Cleaning the Air Filter Element
  94
- Checking the Fuel Line
  96
- Checking the Throttle Body Joint
  96
- Checking the Cylinder Head Breather Hose
  97
- Checking the Exhaust System
  97
- Checking the Coolant Level
  99
- Changing the Coolant
  100
- Checking the Cooling System
  100
- Adjusting the Front Disc Brake
  102
- Adjusting the Rear Disc Brake
  102
- Chassis
  102
- Checking the Brake Fluid Level
  102
- 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
- Adjusting the Front Fork Legs
  107
- Checking the Front Fork Legs
  107
- Lubricating the Steering Head
  107
- Adjusting the Rear Shock Absorber Assembly
  109
- Checking the Rear Shock Absorber Assembly
  109
- Checking the Connecting Arm and Relay Arm
  111
- Checking the Swingarm Operation
  111
- Checking the Tires
  111
- Lubricating the Swingarm Pivot
  111
- Checking and Lubricating the Cables
  112
- Checking and Tightening the Spokes
  112
- Checking the Chassis Fasteners
  112
- Checking the Wheel Bearings
  112
- Checking the Wheels
  112
- Lubricating the Brake Lever
  113
- Lubricating the Clutch Lever
  113
- Lubricating the Pedal
  113
- Checking and Charging the Battery
  114
- Checking the Fuses
  114
- Electrical System
  114
Chassis

115
- General Chassis
  120
- Installing the Shroud
  120
- Removing the Number Plate
  120
- Removing the Seat
  120
- Installing the Side Cover
  121
- Removing the Side Cover
  121
- Front Wheel
  122
- Assembling the Front Wheel
  124
- Checking the Front Wheel
  124
- Disassembling the Front Wheel
  124
- Removing the Front Wheel
  124
- Installing the Front Wheel
  125
- Checking and Replacing the Rear Wheel Sprocket
  129
- Checking the Rear Wheel
  129
- Disassembling the Rear Wheel
  129
- Rear Wheel
  129
- Removing the Rear Wheel
  129
- Assembling the Rear Wheel
  130
- Installing the Rear Wheel
  130
- Front Brake
  133
- Checking the Front Brake Disc
  136
- Introduction
  136
- Replacing the Front Brake Pads
  136
- Assembling the Front Brake Caliper
  138
- Checking the Front Brake Caliper
  138
- Disassembling the Front Brake Caliper
  138
- Removing the Front Brake Caliper
  138
- Installing the Front Brake Caliper
  139
- Assembling the Front Brake Master Cylinder
  140
- Checking the Front Brake Master Cylinder
  140
- Removing the Front Brake Master Cylinder
  140
- Installing the Front Brake Master Cylinder
  141
- Rear Brake
  143
- Checking the Rear Brake Disc
  148
- Introduction
  148
- Replacing the Rear Brake Pads
  148
- Checking the Rear Brake Caliper
  150
- Disassembling the Rear Brake Caliper
  150
- Removing the Rear Brake Caliper
  150
- Assembling the Rear Brake Caliper
  151
- Installing the Rear Brake Caliper
  151
- Assembling the Rear Brake Master Cylinder
  152
- Checking the Rear Brake Master Cylinder
  152
- Removing the Rear Brake Master Cylinder
  152
- Installing the Rear Brake Master Cylinder
  153
- Checking the Handlebar
  157
- Installing the Handlebar
  157
- Removing the Handlebar
  157
- Front Fork
  162
- Disassembling the Front Fork Legs
  164
- Removing the Front Fork Legs
  164
- Checking the Front Fork Legs
  165
- Assembling the Front Fork Legs
  166
- Installing the Front Fork Legs
  172
- Steering Head
  174
- Checking the Steering Head
  176
- Installing the Steering Head
  176
- Removing the Lower Bracket
  176
- Rear Shock Absorber Assembly
  179
- Checking the Rear Shock Absorber Assembly
  182
- Disposing of a Rear Shock Absorber
  182
- Handling the Rear Shock Absorber
  182
- Removing the Rear Shock Absorber Assembly
  182
- Checking the Connecting Arm and Relay Arm
  183
- Installing the Connecting Arm
  183
- Installing the Relay Arm
  183
- Installing the Rear Shock Absorber Assembly
  184
- Swingarm
  186
- Checking the Swingarm
  188
- Installing the Swingarm
  188
- Removing the Swingarm
  188
- Chain Drive
  190
- Checking the Drive Chain
  191
- Removing the Drive Chain
  191
- Checking the Drive Sprocket
  192
- Checking the Rear Wheel Sprocket
  192
- Installing the Drive Chain
  192
Engine

195
- Engine Oil Lubrication Chart
  197
- Lubrication System Chart and Diagrams
  197
- Engine Removal
  198
- Installing the Engine
  203
- Removing the Engine
  203
- Installing the Exhaust Pipe and Muffler
  204
- Camshaft
  206
- Checking the Camshaft
  208
- Removing the Camshaft
  208
- Checking the Timing Chain and Camshaft Sprocket
  209
- Checking the Decompression System
  210
- Checking the Timing Chain Tensioners
  210
- Installing the Camshafts
  210
- Cylinder Head
  213
- Checking the Cylinder Head
  215
- Checking the Timing Chain Guide (Intake Side)
  215
- Installing the Cylinder Head
  215
- Removing the Cylinder Head
  215
- Valves and Valve Springs
  218
- Removing the Valves
  220
- Checking the Valves and Valve Guides
  221
- Checking the Valve Seats
  222
- Checking the Valve Springs
  223
- Checking the Valve Lifters
  224
- Installing the Valves
  224
- Cylinder and Piston
  226
- Checking the Cylinder and Piston
  227
- Removing the Piston
  227
- Checking the Piston Rings
  228
- Checking the Piston Pin
  229
- Installing the Piston and Cylinder
  229
- Generator
  231
- Checking the Generator
  234
- Checking the Woodruff Key
  234
- Installing the Generator
  234
- Removing the Generator
  234
- Electric Starter
  236
- Assembling the Starter Motor
  238
- Checking the Starter Motor
  238
- Checking the Clutch Plates
  244
- Checking the Clutch Spring
  244
- Checking the Friction Plates
  244
- Clutch
  244
- Removing the Clutch
  244
- Checking the Collar
  245
- Checking the Pressure Plate
  245
- Checking the Primary Drive Gear
  245
- Checking the Primary Driven Gear
  245
- Checking the Push Lever Shaft
  245
- Checking the Push Rod
  245
- Assembling the Clutch Release
  246
- Installing the Clutch
  246
- Installing the Clutch Release
  246
- Checking the Shift Shaft
  252
- Checking the Stopper Lever
  252
- Installing the Shift Shaft
  252
- Removing the Segment
  252
- Shift Shaft
  252
- Starter Clutch
  256
- Checking the Starter Clutch
  257
- Installing the Balancer Gear
  257
- Removing the Balancer Gear
  257
- Assembling the Oil Pump
  260
- Checking the Oil Pump
  260
- Installing the Oil Pump
  260
- Oil Pump
  260
- Crankcase
  261
- Checking the Crankcase
  265
- Checking the Timing Chain Guide (Exhaust Side)
  265
- Disassembling the Crankcase
  265
- Assembling the Crankcase
  266
- Checking the Oil Strainer
  266
- Crankshaft and Balancer Shaft
  268
- Checking the Crankshaft
  269
- Removing the Crankshaft
  269
- Installing the Crankshaft
  270
- Transmission
  271
- Checking the Shift Drum Assembly
  274
- Checking the Shift Forks
  274
- Removing the Transmission
  274
- Checking the Transmission
  275
- Installing the Transmission
  275
Cooling System

279
- Cooling System Diagrams
  280
- Radiator
  281
- Checking the Radiator
  283
- Installing the Radiator
  283
- Water Pump
  285
- Assembling the Water Pump
  287
- Checking the Water Pump
  287
- Disassembling the Water Pump
  287
Fuel System

289
- Checking the Fuel Pump Body
  291
- Checking the Fuel Pump Operation
  291
- Fuel Tank
  291
- Installing the Fuel Pump
  291
- Removing the Fuel Pump
  291
- Removing the Fuel Tank
  291
- Installing the Fuel Tank
  292
- Throttle Body
  293
- Checking the Injector
  296
- Checking the Throttle Body
  296
- Adjusting the Throttle Position Sensor
  297
- Checking the Fuel Pressure
  297
- Installing the Air Filter Case Assembly Bracket
  298
Electrical System

299
- Circuit Diagram
  300
- Ignition System
  300
- Troubleshooting
  302
- Circuit Diagram
  306
- Electric Starting System
  306
- Troubleshooting
  308
- Charging System
  310
- Circuit Diagram
  310
- Troubleshooting
  312
- Circuit Diagram
  314
- Fuel Injection System
  314
- Connecting the Yamaha Diagnostic Tool
  316
- Yamaha Diagnostic Tool
  316
- Troubleshooting Details (Fault Code)
  318
- Circuit Diagram
  340
- Fuel Pump System
  340
- Troubleshooting
  342
- Electrical Components
  343
- Checking the Switches
  344
- Checking and Charging the Battery
  346
- Checking the Fuses
  346
- Checking the Relay Unit (Diode)
  348
- Checking the Relays
  348
- REPLACING the ECU (Engine Control Unit)
  348
- Checking the Ignition Coil
  349
- Checking the Ignition Spark Gap
  349
- Checking the Spark Plug Cap
  349
- Checking the Crankshaft Position Sensor
  350
- Checking the Lean Angle Sensor
  350
- Checking the Starter Motor Operation
  350
- Checking the Rectifier/Regulator
  351
- Checking the Stator Coil
  351
- Checking the Coolant Temperature Sensor
  352
- Checking the Throttle Position Sensor Input Voltage
  352
- Checking the Gear Position Switch
  353
- Checking the Intake Air Temperature Sensor
  353
- Checking the Injector
  354
- Checking the Indicator Light
  355
Troubleshooting

357
Tuning

373
- Chassis
  374
- Selection of the Secondary Reduction Ratio (Sprocket)
  374
- Tire Pressure
  374
- Change in Amount and Characteristics of Fork Oil
  375
- Front Fork Setting
  375
- Setting of Spring after Replacement
  375
- Choosing Set Length
  376
- Front Fork Setting Parts
  376
- Rear Suspension Setting
  376
- Rear Shock Absorber Setting Parts
  377
- Setting of Spring after Replacement
  377
- Suspension Setting (Front Fork)
  379
- Suspension Setting (Rear Shock Absorber)
  380

Yamaha YZ450FP 2023 Owner's Manual (162 pages)

Brand: Yamaha | Category: Motorcycle | Size: 6.31 MB

Table of Contents
7
General Information
9
Safety Information
11
For Safety, be Sure to Obey the Following
11
Location of Important Labels
14
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
Instrument and Control Functions
22
Engine Stop Switch
22
Start Switch
22
Launch Control System
22
Lap Time Record Mode
23
Drive Mode
23
Shift Pedal
24
Front Brake Lever
24
Rear Brake Pedal
24
Starter Knob
24
Fuel Tank Cap
24
Starting and Break-In
25
Fuel
25
Starting a Cold Engine
25
Starting a Warm Engine
26
Break-In Procedures
26
Engine Starting Precaution
26
Maintenance after Break-In
27
Major Maintenance
27
Air Filter Maintenance
27
Torque-Check Points
28
Motorcycle Care and Storage
30
Care
30
Storage
31
Specifications
33
General Specifications
34
Engine Specifications
35
Chassis Specifications
37
Electrical Specifications
40
Tightening Torques
41
General Tightening Torque Specifications
41
Maintenance Intervals
52
Pre-Operation Inspection and Maintenance
56
General Inspection and Maintenance
56
Engine
57
Adjusting the Valve Clearance
57
Checking the Engine Idling Speed
58
Checking the Throttle Grip
58
Checking the Spark Plug
59
Checking the Engine Oil Level
59
Changing the Engine Oil
60
Adjusting the Clutch Lever Free Play
61
Adjusting the Clutch Lever Position
62
Cleaning the Air Filter Element
62
Checking the Throttle Body Joint
64
Checking the Fuel Line
64
Checking the Cylinder Head Breather Hose
65
Checking the Exhaust System
65
Checking the Coolant Level
67
Checking the Cooling System
68
Changing the Coolant
68
Chassis
70
Adjusting the Front Disc Brake
70
Adjusting the Rear Disc Brake
70
Checking the Brake Fluid Level
70
Checking the Front Brake Pads
71
Checking the Rear Brake Pads
71
Checking the Front Brake Hose
71
Checking the Rear Brake Hose
72
Checking the Brake Operation
72
Bleeding the Hydraulic Brake System
72
Drive Chain Slack
73
Checking and Adjusting the Steering Head
74
Lubricating the Steering Head
75
Checking the Front Fork Legs
75
Adjusting the Front Fork Legs
76
Checking the Rear Shock Absorber Assembly
77
Adjusting the Rear Shock Absorber Assembly
77
Checking the Swingarm Operation
79
Lubricating the Swingarm Pivot
79
Checking the Tires
79
Checking and Tightening the Spokes
80
Checking the Wheels
80
Checking the Chassis Fasteners
80
Checking and Lubricating the Cables
80
Lubricating the Brake Lever
81
Lubricating the Clutch Lever
81
Lubricating the Pedal
81
Electrical System
82
Checking and Charging the Battery
82
Checking the Fuses
82
General Chassis
85
Removing the Seat
85
Removing the Number Plate
85
Installing the Shroud
85
Removing the Side Cover
86
Installing the Side Cover
86
Front Wheel
87
Removing the Front Wheel
87
Installing the Front Wheel
87
Rear Wheel
88
Removing the Rear Wheel
88
Checking and Replacing the Rear Wheel Sprocket
88
Installing the Rear Wheel
88
Front Brake
90
Replacing the Front Brake Pads
90
Rear Brake
92
Replacing the Rear Brake Pads
92
Handlebar
94
Removing the Handlebar
94
Checking the Handlebar
94
Installing the Handlebar
94
Front Fork
99
Removing the Front Fork Legs
99
Disassembling the Front Fork Legs
99
Checking the Front Fork Legs
100
Assembling the Front Fork Legs
101
Installing the Front Fork Legs
107
Steering Head
110
Removing the Lower Bracket
110
Checking the Steering Head
110
Installing the Steering Head
110
Rear Shock Absorber Assembly
113
Removing the Rear Shock Absorber Assembly
113
Checking the Rear Shock Absorber Assembly
113
Swingarm
114
Removing the Swingarm
114
Chain Drive
115
Removing the Drive Chain
115
Checking the Drive Chain
115
Checking the Drive Sprocket
116
Checking the Rear Wheel Sprocket
116
Installing the Drive Chain
116
Exhaust System
120
Installing the Exhaust Pipe and Muffler
120
Clutch
121
Removing the Clutch
121
Checking the Friction Plates
121
Checking the Clutch Plates
121
Checking the Clutch Spring
121
Checking the Collar
122
Checking the Pressure Plate
122
Checking the Push Lever Shaft
122
Checking the Push Rod
122
Checking the Primary Drive Gear
122
Checking the Primary Driven Gear
122
Assembling the Clutch Release
123
Installing the Clutch Release
123
Installing the Clutch
123
Troubleshooting
135
Troubleshooting
136
General Information
136
TROUBLESHOOTING of ENGINE (Fault Code Not Detected)
136
Troubleshooting of Clutch
139
Troubleshooting of Transmission
141
Troubleshooting of Cooling System
142
Troubleshooting of Brake
143
Troubleshooting of Suspension
143
Troubleshooting of Steering/Handling
145
Troubleshooting of Charging System
146
Tuning
147
Chassis
148
Selection of the Secondary Reduction Ratio (Sprocket)
148
Drive and Rear Wheel Sprockets Setting Parts
148
Tire Pressure
148
Front Fork Setting
149
Change in Amount and Characteristics of Fork Oil
149
Setting of Spring after Replacement
149
Front Fork Setting Parts
150
Rear Suspension Setting
150
Choosing Set Length
150
Setting of Spring after Replacement
151
Rear Shock Absorber Setting Parts
151
Suspension Setting (Front Fork)
153
Suspension Setting (Rear Shock Absorber)
154

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User Manuals: Yamaha YZ450FP 2023 Motocross Motorcycle

Yamaha YZ450FP 2023 Owner's Service Manual (388 pages)

Table of Contents

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel System

Electrical System

Troubleshooting

Tuning

Yamaha YZ450FP 2023 Owner's Manual (162 pages)

Table of Contents

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