Yamaha YZ450FX 2019 Manuals

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

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
- Rear Brake
  
  152
- 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
- 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
- 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
- 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
- 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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