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YZ450F
Yamaha YZ450F User Manual
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CHAIN DRIVE
4-63
EAS1SL5190
CHAIN DRIVE
Removing the drive chain
Job Order
Part name
Q’ty
Servicing Information
Drive sprocket
Refer to “ENGINE REMOVAL” on pag
e 5-1.
1
Drive chain
1
For installation, reverse th
e
removal proce-
dure.
1
T
.R.
75 Nm (7.5 m
lbf)
kgf, 54 ft
T
.R.
7 Nm (0.7 m
lbf)
kgf, 5.1 ft
188
190
Table of Contents
Table of Contents
11
Important Manual Information
6
Safety Information
7
How to Use this Manual
8
General Information
13
Location of Important Labels
15
Description
18
Identification
19
Vehicle Identification Number
19
Engine Serial Number
19
Model Label
19
Features
20
Outline of the Fi System
20
Fi System
21
Included Parts
22
Sidestand
22
Spark Plug Wrench
22
Nipple Wrench
22
Handlebar Protector
22
Fuel Hose Joint Cover
22
Coupler for Connecting Optional Part
22
Important Information
24
Preparation for Removal and Disassembly
24
Replacement Parts
24
Gaskets, Oil Seals and O-Rings
25
Lock Washers/Plates and Cotter Pins
25
Bearings and Oil Seals
25
Circlips
25
Basic Service Information
26
Electrical System
26
Special Tools
29
Control Functions
34
Engine Stop Switch
34
Clutch Lever
34
Shift Pedal
34
Kickstarter Lever
34
Throttle Grip
34
Front Brake Lever
34
Rear Brake Pedal
35
Starter Knob/Idle Screw
35
Fuel Tank Cap
35
Starting and Break-In
36
Fuel
36
Starting a Cold Engine
36
Starting a Warm Engine
37
Break-In Procedures
37
Maintenance after Break-In
38
Major Maintenance
38
Torque-Check Points
39
Cleaning and Storage
41
Cleaning
41
Storage
41
Specifications
43
General Specifications
44
Engine Specifications
45
Chassis Specifications
51
Electrical Specifications
55
Tightening Torques
56
General Tightening Torque Specifications
56
Engine Tightening Torques
57
Chassis Tightening Torques
61
Lubrication Points and Lubricant Types
64
Engine
64
Chassis
66
Lubrication System Chart and Diagrams
68
Lubrication Diagrams
68
Cable Routing Diagram
76
Periodic Checks and Adjustments
87
Maintenance Intervals
89
Pre-Operation Inspection and Maintenance
95
General Inspection and Maintenance
95
Engine
96
Checking the Coolant Level
96
Checking the Cooling System
96
Changing the Coolant
96
Checking the Radiator Cap
97
Checking the Radiator Cap Opening Pressure
97
Checking the Coolant Circulatory System for Leaks
98
Adjusting the Clutch Lever Position
98
Adjusting the Clutch Lever Free Play
98
Adjusting the Throttle Grip Free Play
99
Lubricating the Throttle Cable
100
Cleaning the Air Filter Element
100
Checking the Throttle Body Joint
101
Checking the Breather Hoses
101
Checking the Exhaust System
101
Checking the Fuel Line
102
Checking the Engine Oil Level
102
Changing the Engine Oil
103
Adjusting the Engine Idling Speed
104
Adjusting the Valve Clearance
105
Chassis
109
Bleeding the Brake System
109
Checking the Brake Hose
110
Adjusting the Front Brake
110
Adjusting the Rear Brake
111
Checking the Front Brake Pads
111
Checking the Rear Brake Pads
113
Checking the Rear Brake Pad Insulator
114
Checking the Brake Fluid Level
114
Adjusting the Drive Chain Slack
115
Checking the Front Fork Legs
116
Checking the Front Fork Protector Guide
116
Cleaning the Front Fork Oil Seal and Dust Seal
116
Air Bleeding from Front Fork
116
Adjusting the Front Fork Legs
117
Checking the Swingarm Operation
118
Checking the Rear Suspension
118
Adjusting the Rear Shock Absorber Assembly
118
Checking the Tires
120
Checking and Tightening the Spokes
120
Checking the Wheels
121
Checking the Wheel Bearings
121
Checking and Adjusting the Steering Head
121
Lubricating the Levers
122
Lubricating the Pedal
122
Electrical System
123
Checking the Spark Plug
123
Checking the Ignition Timing
123
Chassis
125
General Chassis
127
Removing the Left Side Cover
128
Removing the Seat
128
Removing the Number Plate
128
Front Wheel
130
Removing the Front Wheel
130
Checking the Front Wheel
130
Disassembling the Front Wheel
131
Assembling the Front Wheel
131
Installing the Front Wheel
132
Rear Wheel
134
Removing the Rear Wheel
134
Checking the Rear Wheel
134
Disassembling the Rear Wheel
134
Checking and Replacing the Rear Wheel Sprocket
134
Assembling the Rear Wheel
135
Installing the Rear Wheel
135
Front Brake
137
Introduction
141
Checking the Front Brake Disc
141
Removing the Front Brake Caliper
141
Disassembling the Front Brake Caliper
141
Checking the Front Brake Caliper
142
Assembling the Front Brake Caliper
142
Installing the Brake Caliper Piston
142
Installing the Front Brake Caliper
143
Removing the Front Brake Master Cylinder
144
Checking the Front Brake Master Cylinder
144
Assembling the Front Brake Master Cylinder
144
Installing the Front Brake Master Cylinder
145
Rear Brake
147
Introduction
151
Checking the Rear Brake Disc
151
Removing the Rear Brake Caliper
152
Disassembling the Rear Brake Caliper
152
Checking the Rear Brake Caliper
152
Assembling the Rear Brake Caliper
152
Installing the Brake Caliper Piston
153
Installing the Rear Brake Caliper
153
Removing the Rear Brake Master Cylinder
154
Checking the Rear Brake Master Cylinder
154
Assembling the Rear Brake Master Cylinder
155
Installing the Rear Brake Master Cylinder
155
Handlebar
159
Removing the Handlebar
159
Checking the Handlebar
159
Installing the Handlebar
159
Front Fork
163
Removing the Front Fork Legs
165
Disassembling the Front Fork Legs
165
Checking the Front Fork Legs
166
Assembling the Front Fork Legs
167
Installing the Front Fork Legs
173
Steering Head
175
Removing the Lower Bracket
176
Checking the Steering Head
176
Installing the Steering Head
176
Rear Shock Absorber Assembly
179
Handling the Rear Shock Absorber
182
Disposing of a Rear Shock Absorber
182
Removing the Rear Shock Absorber Assembly
182
Removing the Bearing
182
Checking the Rear Shock Absorber Assembly
183
Checking the Connecting Arm and Relay Arm
183
Installing the Relay Arm
183
Installing the Rear Shock Absorber Assembly
184
Swingarm
186
Removing the Swingarm
187
Removing the Bearing
187
Checking the Swingarm
187
Installing the Swingarm
188
Chain Drive
189
Removing the Drive Chain
190
Checking the Drive Chain
190
Checking the Drive Sprocket
191
Checking the Rear Wheel Sprocket
191
Installing the Drive Chain
191
Engine
193
Engine Removal
196
Removing the Drive Sprocket
201
Removing the Exhaust Pipe 2
201
Removing the Silencer
201
Changing the Silencer Fiber
202
Checking the Silencer and Exhaust Pipe
202
Removing the Engine
202
Installing the Engine
203
Installing the Brake Pedal
204
Installing the Drive Sprocket
204
Installing the Exhaust Pipe and Muffler
205
Camshaft
206
Removing the Camshaft
208
Checking the Camshaft
209
Checking the Timing Chain and Camshaft Sprocket
210
Checking the Timing Chain Tensioners
210
Checking the Decompression System
211
Installing the Camshafts
211
Cylinder Head
214
Removing the Cylinder Head
216
Checking the Timing Chain Guide (Intake Side)
216
Checking the Cylinder Head
216
Installing the Cylinder Head
217
Valves and Valve Springs
220
Removing the Valves
220
Checking the Valves and Valve Guides
221
Checking the Valve Seats
222
Checking the Valve Springs
224
Checking the Valve Lifters
224
Installing the Valves
225
Cylinder and Piston
228
Removing the Piston
228
Checking the Cylinder and Piston
228
Checking the Piston Rings
229
Checking the Piston Pin
230
Installing the Piston and Cylinder
230
Clutch
233
Removing the Clutch
235
Checking the Friction Plates
235
Checking the Clutch Plates
235
Checking the Clutch Springs
235
Checking the Clutch Housing
236
Checking the Clutch Boss
236
Checking the Pressure Plate
236
Checking the Push Lever Shaft
236
Checking the Clutch Push Rods
236
Checking the Primary Drive Gear
236
Checking the Primary Driven Gear
237
Installing the Oil Seal
237
Installing the Right Crankcase Cover
237
Installing the Clutch
237
Installing the Kickstarter Lever
240
Kickstater
242
Removing the Kick Shaft Assembly
242
Checking the Kick Shaft and Ratchet Wheel
242
Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
242
Installing the Kick Shaft Assembly
242
Installing the Kick Idle Gear
243
Shift Shaft
244
Removing the Shift Guide and Shift Lever Assembly
246
Removing the Segment
246
Checking the Shift Shaft
246
Checking the Shift Guide and Shift Lever Assembly
246
Checking the Stopper Lever
246
Installing the Stopper Lever
247
Installing the Segment
247
Installing the Shift Guide and Shift Lever Assembly
247
Installing the Shift Shaft
248
Installing the Shift Pedal
248
Oil Pump and Balancer Gear
250
Removing the Balancer
251
Checking the Primary Drive Gear, Balancer Shaft Drive Gear, and Balancer Weight Gear
251
Checking the Balancer
251
Checking the Oil Pump
251
Assembling the Oil Pump
252
Installing the Oil Pump and Balancer Gear
252
Ac Magneto
254
Removing the Ac Magneto
255
Checking the Ac Magneto
255
Checking the Woodruff Key
255
Installing the Ac Magneto
255
Crankcase
257
Disassembling the Crankcase
260
Removing the Crankcase Bearing
260
Checking the Timing Chain, Timing Chain Guide, Oil Strainer
260
Checking the Crankcase
260
Assembling the Crankcase
261
Crankshaft Assembly and Balancer Shaft
262
Removing the Balancer Shaft
263
Removing the Crankshaft Assembly
263
Checking the Crankshaft Assembly
263
Installing the Crankshaft Assembly
264
Transmission
266
Removing the Transmission
266
Checking the Shift Forks
266
Checking the Shift Drum Assembly
267
Checking the Transmission
267
Installing the Transmission
267
Cooling System
271
Fuel System
279
Fuel Tank
280
Checking the Fuel Pump Body
281
Installing the Fuel Pump
281
Removing the Fuel Pump
281
Removing the Fuel Tank
281
Checking the Fuel Pressure
282
Installing the Fuel Tank
282
Checking and Replacing the Protector
283
Checking the Damper
283
Throttle Body
284
Checking the Injector
287
Checking the Throttle Body
287
Checking the Throttle Body Joint
287
Adjusting the Throttle Position Sensor
288
Electrical System
289
Ignition System
292
Circuit Diagram
292
Troubleshooting
294
Charging System
296
Circuit Diagram
296
Troubleshooting
298
Fuel Injection System
300
Circuit Diagram
300
Yamaha Diagnostic Tool
302
Troubleshooting Details
303
Fuel Pump System
322
Circuit Diagram
322
Troubleshooting
324
Electrical Components
326
Checking the Switches
328
Checking the Ignition Spark Gap
331
Checking the Spark Plug Cap
331
Checking the Ignition Coil
331
Checking the Crankshaft Position Sensor
332
Checking the Ecu
333
Checking the Stator Coil
333
Checking the Rectifier/Regulator
333
Checking the Coolant Temperature Sensor
334
Checking the Throttle Position Sensor
334
Checking the Throttle Position Sensor Input Voltage
335
Checking the Intake Air Pressure Sensor
336
Checking the Intake Air Temperature Sensor
336
Checking the Neutral Switch
336
Checking the Fuel Injector
337
Troubleshooting
339
Default Chapter
339
General Information
339
Troubleshooting
340
General Information
340
Incorrect Engine Idling Speed
340
Starting Failures
340
Faulty Clutch
341
Faulty Gear Shifting
341
Jumps out of Gear
341
Overheating
341
Poor Medium-And-High-Speed Performance
341
Shift Pedal Does Not Move
341
Faulty Front Fork Legs
342
Overcooling
342
Poor Braking Performance
342
Unstable Handling
342
List of Self-Diagnostic and Fail-Safe Actions
343
Tuning
347
Chassis
348
Drive and Rear Wheel Sprockets Setting Parts
348
Selection of the Secondary Reduction Ratio (Sprocket)
348
Change in Amount and Characteristics of Fork Oil
349
Front Fork Setting
349
Tire Pressure
349
Choosing Set Length
350
Front Fork Setting Parts
350
Rear Suspension Setting
350
Setting of Spring after Replacement
350
Setting of Spring after Replacement
351
Rear Shock Absorber Setting Parts
352
Suspension Setting (Front Fork)
353
Suspension Setting (Rear Shock Absorber)
354
Wiring Diagram
356
Other manuals for Yamaha YZ450F
Owner's Manual
224 pages
Parts Catalogue
67 pages
5
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Yamaha YZ450F Specifications
General
Brand
Yamaha
Model
YZ450F
Category
Motorcycle
Language
English
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