Yamaha YZ450FR Owner's Service Manual
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Yamaha YZ450FR Owner's Service Manual

Yamaha YZ450FR Owner's Service Manual

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OWNER'S SERVICE MANUAL
YZ450FR
LIT-11626-16-38
5TA-28199-10

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Summary of Contents for Yamaha YZ450FR

  • Page 1 OWNER’S SERVICE MANUAL YZ450FR LIT-11626-16-38 5TA-28199-10...
  • Page 2 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.

  • Page 4: Important Notice

    IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regula- tions before riding.
  • Page 5 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.

  • Page 6: To The New Owner

    If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold.

  • Page 7: How To Use This Manual

    EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

  • Page 8: Manual Format

    EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., Bearings...

  • Page 9: Illustrated Symbols

    ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC Illustrated symbols 1 to 7 are designed as INFO thumb tabs to indicate the chapter’s number and content. 1 General information INSP 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical –...
  • Page 10 MEMO...
  • Page 11 EC090000 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC REGULAR INSPECTION AND INSP ADJUSTMENTS ENGINE CHASSIS CHAS – ELECTRICAL ELEC TUNING...
  • Page 12 EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......... 1-1 MACHINE IDENTIFICATION ....1-2 IMPORTANT INFORMATION ....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS ........1-7 CONTROL FUNCTIONS ......1-10 FUEL ............1-13 STARTING AND BREAK-IN ....1-14 TORQUE-CHECK POINTS ..... 1-18 CLEANING AND STORAGE ....
  • Page 13 CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ......... 4-1 EXHAUST PIPE AND SILENCER .... 4-3 RADIATOR ..........4-5 CARBURETOR ......... 4-8 CAMSHAFTS .......... 4-21 CYLINDER HEAD ........4-29 VALVES AND VALVE SPRINGS ... 4-33 CYLINDER AND PISTON ....... 4-42 CLUTCH ..........
  • Page 14 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ......6-1 MAP-CONTROLLED CDI UNIT ....6-2 IGNITION SYSTEM ........6-3 TPS (THROTTLE POSITION SENSOR) SYSTEM ............ 6-7 CHAPTER 7 TUNING ENGINE ............. 7-1 CHASSIS ..........7-10...
  • Page 15 DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION NOTE: 1 Clutch lever The machine you have purchased may differ 2 Hot starter lever slightly from those shown in the following. 3 Front brake lever 4 Throttle grip Designs and specifications are subject to 5 Radiator cap change without notice.

  • Page 16: Vehicle Identification Number

    There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for posi- tive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

  • Page 17: Preparation For Removal And Disassembly

    IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts as fol- lows. Silencer exhaust port Side cover air intake port Water pump housing hole at the bottom...
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