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YZ450FX 2019
Yamaha YZ450FX 2019 Manuals
Manuals and User Guides for Yamaha YZ450FX 2019. We have
1
Yamaha YZ450FX 2019 manual available for free PDF download: Owner's Service Manual
Yamaha YZ450FX 2019 Owner's Service Manual (388 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 45.9 MB
Table of Contents
Table of Contents
11
Location of Important Labels
15
Description
16
Identification
17
Vehicle Identification Number
17
Engine Serial Number
17
Included Parts
18
Nipple Wrench
18
Handlebar Protector
18
Fuel Hose Joint Cover
18
Power Tuner
18
Important Information
20
Preparation for Removal and Disassembly
20
Replacement Parts
20
Gaskets, Oil Seals and O-Rings
21
Lock Washers/Plates and Cotter Pins
21
Bearings and Oil Seals
21
Circlips
21
Basic Service Information
22
Electrical System
22
Special Tools
26
Control Functions
32
Warning Lights
32
Engine Stop Switch
32
Start Switch
32
Mode Switch
32
Clutch Lever
33
Shift Pedal
33
Throttle Grip
33
Front Brake Lever
33
Rear Brake Pedal
33
Sidestand
33
Starter Knob
34
Fuel Tank Cap
34
Fuel
35
Air Filter Maintenance
35
Starting a Cold Engine
35
Starting a Warm Engine
36
Break-In Procedures
36
Engine Starting Precaution
36
Starting and Break-In
35
Maintenance after Break-In
37
Major Maintenance
37
Torque-Check Points
38
Motorcycle Care and Storage
40
Care
40
Storage
41
Specifications
43
General Specifications
44
Engine Specifications
45
Chassis Specifications
50
Electrical Specifications
52
Tightening Torques
53
General Tightening Torque Specifications
53
Engine Tightening Torques
54
Chassis Tightening Torques
57
Lubrication Points and Lubricant Types
60
Engine
60
Chassis
61
Lubrication System Chart and Diagrams
64
Lubrication Diagrams
64
Cable Routing Diagram
74
Periodic Checks and Adjustments
87
Maintenance Intervals
89
Pre-Operation Inspection and Maintenance
93
General Inspection and Maintenance
93
Changing the Coolant
94
Checking the Coolant Level
94
Checking the Cooling System
94
Engine
94
Checking the Radiator Cap
95
Checking the Radiator Cap Valve Opening Pressure
95
Adjusting the Clutch Lever Free Play
96
Adjusting the Clutch Lever Position
96
Checking the Coolant Circulatory System for Leaks
96
Adjusting the Throttle Grip Free Play
97
Cleaning the Air Filter Element
98
Lubricating the Throttle Cable
98
Checking the Breather Hoses
100
Checking the Exhaust System
100
Checking the Throttle Body Joint
100
Checking the Engine Oil Level
101
Checking the Fuel Line
101
Changing the Engine Oil
102
Adjusting the Engine Idling Speed
103
Adjusting the Valve Clearance
104
Valve Clearance Shim Chart
107
Chassis
109
Bleeding the Brake System
109
Checking the Brake Hoses
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
Lubricating the Drive Chain
122
Lubricating the Sidestand
122
Checking the Chassis Fasteners
123
Electrical System
124
Checking the Spark Plug
124
Checking the Ignition Timing
124
Checking and Charging the Battery
125
Chassis
127
General Chassis
131
Removing the Seat
131
Removing the Number Plate
131
Installing the Air Scoop
131
Removing the Side Cover
132
Installing the Side Cover
132
Front Wheel
134
Removing the Front Wheel
134
Checking the Front Wheel
134
Disassembling the Front Wheel
135
Assembling the Front Wheel
135
Installing the Front Wheel
136
Rear Wheel
138
Removing the Rear Wheel
138
Checking the Rear Wheel
138
Disassembling the Rear Wheel
138
Checking and Replacing the Rear Wheel Sprocket
138
Assembling the Rear Wheel
139
Installing the Rear Wheel
139
Front Brake
142
Introduction
145
Checking the Front Brake Disc
145
Removing the Front Brake Caliper
145
Disassembling the Front Brake Caliper
145
Checking the Front Brake Caliper
146
Assembling the Front Brake Caliper
146
Installing the Brake Caliper Piston
146
Installing the Front Brake Caliper
147
Removing the Front Brake Master Cylinder
148
Checking the Front Brake Master Cylinder
148
Assembling the Front Brake Master Cylinder
148
Installing the Front Brake Master Cylinder
149
Rear Brake
152
Introduction
155
Checking the Rear Brake Disc
155
Removing the Rear Brake Caliper
156
Disassembling the Rear Brake Caliper
156
Checking the Rear Brake Caliper
156
Assembling the Rear Brake Caliper
156
Installing the Brake Caliper Piston
157
Installing the Rear Brake Caliper
157
Removing the Rear Brake Master Cylinder
158
Checking the Rear Brake Master Cylinder
158
Assembling the Rear Brake Master Cylinder
159
Installing the Rear Brake Master Cylinder
159
Handlebar
161
Removing the Handlebar
162
Checking the Handlebar
162
Installing the Handlebar
162
Front Fork
166
Removing the Front Fork Legs
168
Disassembling the Front Fork Legs
168
Checking the Front Fork Legs
169
Assembling the Front Fork Legs
170
Installing the Front Fork Legs
176
Steering Head
179
Removing the Lower Bracket
180
Checking the Steering Head
180
Installing the Steering Head
180
Rear Shock Absorber Assembly
183
Handling the Rear Shock Absorber
185
Disposing of a Rear Shock Absorber
185
Removing the Rear Shock Absorber Assembly
185
Removing the Bearing
185
Checking the Rear Shock Absorber Assembly
186
Checking the Connecting Arm and Relay Arm
186
Installing the Relay Arm
186
Installing the Rear Shock Absorber Assembly
187
Swingarm
189
Removing the Swingarm
190
Removing the Bearing
190
Checking the Swingarm
190
Installing the Swingarm
190
Chain Drive
192
Removing the Drive Chain
193
Checking the Drive Chain
193
Checking the Drive Sprocket
194
Checking the Rear Wheel Sprocket
194
Installing the Drive Chain
194
Engine
197
Engine Removal
204
Removing the Silencer
204
Removing the Exhaust Pipe 2
204
Removing the Drive Sprocket
204
Removing the Engine
204
Checking the Silencer and Exhaust Pipe
205
Changing the Silencer Fiber
205
Installing the Engine
207
Installing the Brake Pedal
207
Installing the Drive Sprocket
207
Installing the Exhaust Pipe and Muffler
208
Camshaft
210
Removing the Camshaft
212
Checking the Camshaft
213
Checking the Timing Chain and Camshaft Sprocket
214
Checking the Timing Chain Tensioners
214
Checking the Decompression System
215
Installing the Camshafts
215
Cylinder Head
218
Removing the Cylinder Head
220
Checking the Timing Chain Guide (Intake Side)
220
Checking the Cylinder Head
220
Installing the Cylinder Head
221
Valves and Valve Springs
224
Removing the Valves
224
Checking the Valves and Valve Guides
225
Checking the Valve Seats
226
Checking the Valve Springs
228
Checking the Valve Lifters
228
Installing the Valves
228
Cylinder and Piston
231
Removing the Piston
231
Checking the Cylinder and Piston
231
Checking the Piston Rings
232
Checking the Piston Pin
233
Installing the Piston and Cylinder
233
Electric Starter
235
Checking the Starter Motor
237
Assembling the Starter Motor
238
Clutch
239
Removing the Clutch
242
Checking the Friction Plates
242
Checking the Clutch Plates
242
Checking the Clutch Springs
242
Checking the Clutch Housing
243
Checking the Clutch Boss
243
Checking the Pressure Plate
243
Checking the Push Lever Shaft
243
Checking the Clutch Push Rods
243
Checking the Primary Drive Gear
243
Checking the Primary Driven Gear
244
Installing the Oil Seal
244
Installing the Right Crankcase Cover
244
Installing the Clutch
244
Shift Shaft
247
Removing the Shift Guide and Shift Lever Assembly
248
Removing the Segment
248
Checking the Shift Shaft
248
Checking the Shift Guide and Shift Lever Assembly
248
Checking the Stopper Lever
248
Installing the Stopper Lever
248
Installing the Segment
249
Installing the Shift Guide and Shift Lever Assembly
249
Installing the Shift Shaft
250
Installing the Shift Pedal
250
Oil Pump and Balancer Gear
253
Removing the Balancer
253
Checking the Primary Drive Gear, Balancer Drive Gear, and Balancer Weight Gear
253
Checking the Balancer
253
Checking the Oil Pump
253
Assembling the Oil Pump
254
Installing the Oil Pump and Balancer Gear
254
Ac Magneto
256
Removing the Ac Magneto
257
Checking the Ac Magneto
257
Checking the Woodruff Key
257
Installing the Ac Magneto
257
Starter Clutch
259
Checking the Starter Clutch
260
Crankcase
261
Disassembling the Crankcase
263
Removing the Crankcase Bearing
263
Checking the Timing Chain, Timing Chain Guide, Oil Strainer
263
Checking the Crankcase
263
Installing the Oil Seal
264
Assembling the Crankcase
264
Crankshaft Assembly and Balancer Shaft
266
Removing the Balancer Shaft
267
Removing the Crankshaft Assembly
267
Checking the Crankshaft Assembly
267
Installing the Crankshaft Assembly
268
Transmission
269
Removing the Transmission
270
Checking the Shift Forks
270
Checking the Shift Drum Assembly
270
Checking the Transmission
271
Installing the Transmission
271
Cooling System
275
Fuel System
283
Checking the Fuel Pump Body
285
Fuel Tank
285
Fuel Tank
285
Installing the Fuel Pump
285
Removing the Fuel Pump
285
Removing the Fuel Tank
285
Checking the Fuel Pressure
286
Installing the Fuel Tank
286
Checking the Damper
287
Throttle Body
288
Checking the Injector
291
Checking the Throttle Body
291
Checking the Throttle Body Joint
291
Adjusting the Throttle Position Sensor
292
Electrical System
293
Ignition System
296
Circuit Diagram
296
Troubleshooting
298
Electric Starting System
300
Circuit Diagram
300
Troubleshooting
302
Charging System
304
Circuit Diagram
304
Troubleshooting
306
Signaling System
308
Circuit Diagram
308
Troubleshooting
310
COOLING SYSTEM (for JPN)
312
Circuit Diagram
312
Troubleshooting
314
Fuel Injection System
316
Circuit Diagram
316
Ecu Self-Diagnostic Function
318
Troubleshooting Method
319
Yamaha Diagnostic Tool
320
Features of the Yamaha Diagnostic Tool
321
Functions of the Yamaha Diagnostic Tool
321
Connecting the Yamaha Diagnostic Tool
321
Troubleshooting Details (Fault Code)
323
Fuel Pump System
342
Circuit Diagram
342
Troubleshooting
344
Electrical Components
346
Checking the Switches
350
Checking the Bulbs and Bulb Sockets
353
Checking the Fuses
353
Checking and Charging the Battery
354
Checking the Relays
356
Checking the Diode
356
Checking the Ignition Spark Gap
357
Checking the Spark Plug Cap
357
Checking the Ignition Coil
358
Checking the Crankshaft Position Sensor
358
Checking the Ecu
359
Checking the Starter Motor Operation
359
Checking the Stator Coil
359
Checking the Rectifier/Regulator
360
Checking the Fuel Sender
360
Checking the Resistor
360
CHECKING the RADIATOR FAN MOTOR (for JPN)
361
Checking the Coolant Temperature Sensor
361
Checking the Throttle Position Sensor Input Voltage
362
Checking the Intake Air Temperature Sensor
362
Checking the Gear Position Switch
363
Checking the Fuel Injector
363
Troubleshooting
365
Troubleshooting
366
General Information
366
Incorrect Engine Idling Speed
366
Starting Failure
366
Clutch Drags
367
Clutch Slips
367
Jumps out of Gear
367
Overheating
367
Poor Medium-And-High-Speed Performance
367
Shift Pedal Does Not Move
367
Shifting Is Difficult
367
Faulty Front Fork Legs
368
Front Fork Oil Leaking
368
Overcooling
368
Poor Braking Performance
368
Unstable Handling
368
List of Self-Diagnostic and Fail-Safe Actions
369
List of Diagnostic Codes
369
Sensor Operation Table
370
Actuator Operation Table
371
Tuning
373
Chassis
374
Drive and Rear Wheel Sprockets Setting Parts
374
Selection of the Secondary Reduction Ratio (Sprocket)
374
Tire Pressure
374
Change in Amount and Characteristics of Fork Oil
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
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