Yamaha YZ450FG Manuals

Manuals and User Guides for Yamaha YZ450FG. We have 1 Yamaha YZ450FG manual available for free PDF download: Owner's Service Manual

Yamaha YZ450FG Owner's Service Manual

Yamaha YZ450FG Owner's Service Manual (362 pages)

2016

Brand: Yamaha | Category: Motorcycle | Size: 11 MB

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
  - Included Parts
    20
    
    Sidestand
    20
    
    Spark Plug Wrench
    20
    
    Nipple Wrench
    20
    
    Handlebar Protector
    20
    
    Fuel Hose Joint Cover
    20
    
    Coupler for Connecting Optional Part
    20
  - Important Information
    22
    
    Preparation for Removal and Disassembly
    22
    
    Replacement Parts
    22
    
    Gaskets, Oil Seals and O-Rings
    23
    
    Lock Washers/Plates and Cotter Pins
    23
    
    Bearings and Oil Seals
    23
    
    Circlips
    23
  - Basic Service Information
    24
    
    Electrical System
    24
  - Special Tools
    27
  - Control Functions
    32
    
    Engine Stop Switch
    32
    
    Launch Control Switch
    32
    
    Clutch Lever
    32
    
    Shift Pedal
    32
    
    Kickstarter Lever
    33
    
    Throttle Grip
    33
    
    Front Brake Lever
    33
    
    Rear Brake Pedal
    33
    
    Starter Knob/Idle Screw
    33
    
    Fuel Tank Cap
    34
  - Starting and Break-In
    35
    
    Fuel
    35
    
    Starting a Cold Engine
    35
    
    Starting a Warm Engine
    36
    
    Break-In Procedures
    36
  - Maintenance after Break-In
    37
    
    Major Maintenance
    37
  - Torque-Check Points
    38
  - Cleaning and Storage
    40
    
    Cleaning
    40
    
    Storage
    40
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  48
- Electrical Specifications
  52
- Tightening Torques
  53
- Lubrication Points and Lubricant Types
  61
  - Engine
    61
  - Chassis
    62
- Lubrication System Chart and Diagrams
  64
  - Lubrication Diagrams
    64
- Cable Routing Diagram
  72
Periodic Checks and Adjustments

83
- Maintenance Intervals
  
  85
- Pre-Operation Inspection and Maintenance
  
  91
  - General Inspection and Maintenance
    91
- Engine
  
  92
- Chassis
  
  106
  - Bleeding the Brake System
    106
    
    Checking the Brake Hose
    107
    
    Adjusting the Front Brake
    107
    
    Adjusting the Rear Brake
    108
    
    Checking the Front Brake Pads
    108
    
    Checking the Rear Brake Pads
    110
    
    Checking the Rear Brake Pad Insulator
    111
    
    Checking the Brake Fluid Level
    111
    
    Adjusting the Drive Chain Slack
    112
    
    Checking the Front Fork Legs
    113
    
    Checking the Front Fork Protector Guide
    113
    
    Cleaning the Front Fork Oil Seal and Dust Seal
    113
    
    Air Bleeding from Front Fork
    114
    
    Adjusting the Front Fork Legs
    114
    
    Checking the Swingarm Operation
    115
    
    Checking the Rear Suspension
    115
    
    Adjusting the Rear Shock Absorber Assembly
    115
    
    Checking the Tires
    118
    
    Checking and Tightening the Spokes
    118
    
    Checking the Wheels
    118
    
    Checking the Wheel Bearings
    118
    
    Checking and Adjusting the Steering Head
    119
    
    Lubricating the Levers
    120
    
    Lubricating the Pedal
    120
- Electrical System
  
  121
  - Checking the Spark Plug
    121
  - Checking the Ignition Timing
    121
Chassis

123
- General Chassis
  
  125
  - Removing the Left Side Cover
    126
  - Removing the Seat
    126
  - Removing the Number Plate
    126
- Front Wheel
  
  127
  - Removing the Front Wheel
    128
  - Checking the Front Wheel
    128
  - Disassembling the Front Wheel
    129
  - Assembling the Front Wheel
    129
  - Installing the Front Wheel
    130
- Rear Wheel
  
  131
  - Removing the Rear Wheel
    132
  - Checking the Rear Wheel
    132
  - Disassembling the Rear Wheel
    132
  - Checking and Replacing the Rear Wheel Sprocket
    132
  - Assembling the Rear Wheel
    133
  - Installing the Rear Wheel
    134
- Front Brake
  
  136
- Rear Brake
  
  146
- Handlebar
  
  158
  - Removing the Handlebar
    158
  - Checking the Handlebar
    158
  - Installing the Handlebar
    158
- Front Fork
  
  162
  - Removing the Front Fork Legs
    164
  - Disassembling 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
  
  175
  - Removing the Lower Bracket
    176
  - Checking the Steering Head
    176
  - Installing the Steering Head
    176
- Rear Shock Absorber Assembly
  
  179
- 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
  
  207
  - Removing the Camshaft
    209
  - Checking the Camshaft
    210
  - Checking the Timing Chain and Camshaft Sprocket
    211
  - Checking the Timing Chain Tensioners
    211
  - Checking the Decompression System
    212
  - Installing the Camshafts
    212
- Cylinder Head
  
  215
- Valves and Valve Springs
  
  221
  - Removing the Valves
    221
  - Checking the Valves and Valve Guides
    222
  - Checking the Valve Seats
    223
  - Checking the Valve Springs
    225
  - Checking the Valve Lifters
    226
  - Installing the Valves
    226
- Cylinder and Piston
  
  229
  - Removing the Piston
    229
  - Checking the Cylinder and Piston
    229
  - Checking the Piston Rings
    230
  - Checking the Piston Pin
    231
  - Installing the Piston and Cylinder
    231
- Clutch
  
  234
  - Removing the Clutch
    236
  - Checking the Friction Plates
    236
  - Checking the Clutch Plates
    236
  - Checking the Clutch Springs
    236
  - Checking the Clutch Housing
    237
  - Checking the Clutch Boss
    237
  - Checking the Pressure Plate
    237
  - Checking the Push Lever Shaft
    237
  - Checking the Clutch Push Rods
    237
  - Checking the Primary Drive Gear
    237
  - Checking the Primary Driven Gear
    238
  - Installing the Oil Seal
    238
  - Installing the Right Crankcase Cover
    238
  - Installing the Clutch
    239
  - Installing the Kickstarter Lever
    241
- Kickstater
  
  243
- Shift Shaft
  
  245
  - Removing the Shift Guide and Shift Lever Assembly
    247
  - Removing the Segment
    247
  - Checking the Shift Shaft
    247
  - Checking the Shift Guide and Shift Lever Assembly
    247
  - Checking the Stopper Lever
    247
  - Installing the Stopper Lever
    248
  - Installing the Segment
    248
  - Installing the Shift Guide and Shift Lever Assembly
    248
  - Installing the Shift Shaft
    249
  - Installing the Shift Pedal
    249
- Oil Pump and Balancer Gear
  
  251
- Ac Magneto
  
  256
  - Removing the Ac Magneto
    257
  - Checking the Ac Magneto
    257
  - Checking the Woodruff Key
    257
  - Installing the Ac Magneto
    257
- Crankcase
  
  259
- Crankshaft Assembly and Balancer Shaft
  
  264
- Transmission
  
  267
  - Removing the Transmission
    268
  - Checking the Shift Forks
    268
  - Checking the Shift Drum Assembly
    269
  - Checking the Transmission
    269
  - Installing the Transmission
    269
  - Cooling System
    273
Fuel System

281
- Fuel Tank
  
  282
  - Checking the Fuel Pump Body
    283
  - Installing the Fuel Pump
    283
  - Removing the Fuel Pump
    283
  - Removing the Fuel Tank
    283
  - Checking the Fuel Pressure
    284
  - Installing the Fuel Tank
    284
  - Checking and Replacing the Protector
    285
  - Checking the Damper
    285
- Throttle Body
  
  288
  - Checking the Injector
    289
  - Checking the Throttle Body
    289
  - Checking the Throttle Body Joint
    289
  - Adjusting the Throttle Position Sensor
    290
Electrical System

291
- Ignition System
  
  294
  - Circuit Diagram
    294
  - Troubleshooting
    296
- Charging System
  
  298
  - Circuit Diagram
    298
  - Troubleshooting
    300
- Fuel Injection System
  
  302
  - Circuit Diagram
    302
  - Yamaha Diagnostic Tool
    304
  - Troubleshooting Details
    305
- Fuel Pump System
  
  324
  - Circuit Diagram
    324
  - Troubleshooting
    326
- Electrical Components
  
  328
  - Checking the Switches
    330
  - Checking the Ignition Spark Gap
    333
  - Checking the Spark Plug Cap
    333
  - Checking the Ignition Coil
    333
  - Checking the Crankshaft Position Sensor
    334
  - Checking the Ecu
    334
  - Checking the Stator Coil
    334
  - Checking the Rectifier/Regulator
    335
  - Checking the Coolant Temperature Sensor
    335
  - Checking the Throttle Position Sensor
    336
  - Checking the Throttle Position Sensor Input Voltage
    337
  - Checking the Intake Air Pressure Sensor
    337
  - Checking the Intake Air Temperature Sensor
    337
  - Checking the Neutral Switch
    338
  - Checking the Fuel Injector
    338
Troubleshooting

341
- General Information
  341
- Troubleshooting
  
  342
  - General Information
    342
  - Incorrect Engine Idling Speed
    342
  - Starting Failures
    342
  - Clutch Drags
    343
  - Clutch Slips
    343
  - Jumps out of Gear
    343
  - Overheating
    343
  - Poor Medium-And-High-Speed Performance
    343
  - Shift Pedal Does Not Move
    343
  - Shifting Is Difficult
    343
  - Faulty Front Fork Legs
    344
  - Front Fork Oil Leaking
    344
  - Overcooling
    344
  - Poor Braking Performance
    344
  - Unstable Handling
    344
- List of Self-Diagnostic and Fail-Safe Actions
  
  345
Tuning

349
- Chassis
  350
- Selection of the Secondary Reduction Ratio (Sprocket)
  350
- Change in Amount and Characteristics of Fork Oil
  351
- Front Fork Setting
  351
- Tire Pressure
  351
- Choosing Set Length
  352
- Front Fork Setting Parts
  352
- Rear Suspension Setting
  352
- Setting of Spring after Replacement
  352
- Setting of Spring after Replacement
  353
- Rear Shock Absorber Setting Parts
  354
- Suspension Setting (Front Fork)
  355
- Suspension Setting (Rear Shock Absorber)
  356
  - Wiring Diagram
    358

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