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Yamaha YZ450F 2010 Service Manual

Yamaha YZ450F 2010
230 pages
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OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
YZ450F
(
Z
)
33D-28199-80
PRINTED IN JAPAN
2009.07—2.1 × 1 !
(E, F, G)
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED ON RECYCLED PAPER
2010
YZ450F
(
Z
)
2010
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
q
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
33D-9-80cover 09.7.16 13:46 ページ1

Table of Contents

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Yamaha YZ450F 2010 Specifications

General IconGeneral
Engine Type449cc liquid-cooled DOHC 4-stroke; 4 titanium valves
Compression Ratio12.5:1
Fuel DeliveryFuel Injection
Transmission5-speed; multiplate wet clutch
Final DriveChain
Front BrakeHydraulic single disc brake, 250mm
Rear BrakeHydraulic single disc brake, 245mm
Front Tire80/100-21
Rear Tire120/80-19
Width32.5 in
Wheelbase58.5 in
Fuel Capacity1.6 gal
Wet Weight245 lb
Bore x Stroke97.0mm x 60.8mm
Front Suspension12.2-in travel

Summary

FOREWORD

INTRODUCTION

Provides an overview of the Yamaha YZ series and the manual's purpose.

SAFETY INFORMATION

Outlines crucial safety guidelines, warnings for competition use, and protective apparel.

HOW TO USE THIS MANUAL

F.I.M. MACHINE WEIGHTS

Lists minimum weight requirements for motocross machines according to F.I.M. regulations.

FINDING THE REQUIRED PAGE

Explains how to navigate the manual using chapters and fore-edge symbols for efficient searching.

MANUAL FORMAT

Describes the sequential, step-by-step format of procedures for clear disassembly and repair instructions.

DESCRIPTION GUIDELINES

HOW TO READ DESCRIPTIONS

Explains how to interpret exploded diagrams and procedure steps in the manual.

ILLUSTRATED SYMBOLS EXPLANATION

Explains the meaning of illustrated symbols used for specifications and lubrication points.

IMPORTANT LABELS LOCATIONS

CANADA LABELS

Identifies important labels specific to Canada, including fuel and safety warnings.

EUROPE LABELS

Identifies important labels for Europe, including CE marking and safety warnings.

AUS, NZ, ZA LABELS

Identifies important labels for Australia, New Zealand, and South Africa, including safety warnings.

PICTOGRAM EXPLANATIONS

Explains pictograms used for warnings and operational guidance, such as manual reading and tire pressure.

VEHICLE DESCRIPTION

VEHICLE COMPONENTS DIAGRAM

Lists and labels various parts of the vehicle in an exploded diagram for identification.

CONSUMER INFORMATION

SERIAL NUMBER IMPORTANCE

Explains the importance of serial numbers for parts ordering and theft identification.

VEHICLE AND ENGINE IDENTIFICATION

Locates vehicle identification numbers and engine serial numbers on the frame and engine.

MODEL LABEL LOCATION

Identifies the location of the model label affixed under the rider's seat for spare parts.

VEHICLE FEATURES

FUEL INJECTION (FI) SYSTEM OVERVIEW

Outlines the FI system and its main components, including sensors and the ECU.

FI SYSTEM OPERATION

Explains the operation of the fuel pump, injector, pressure regulator, and ECU in the FI system.

PARTS AND HANDLING INFORMATION

INCLUDED PARTS DESCRIPTION

Lists and describes included accessories such as a detachable sidestand and tools.

PREPARATION FOR DISASSEMBLY

Provides preparation advice for removal/disassembly, tool usage, and part handling.

HANDLING ELECTRONIC PARTS

Warns about static electricity and emphasizes careful handling of sensitive electronic components.

CHECKING ELECTRICAL CONNECTIONS

Details how to check electrical connections for stains, rust, and moisture to ensure proper function.

SPECIAL TOOLS REQUIRED

Lists special tools with part numbers and their uses for engine, chassis, and electrical maintenance.

VEHICLE CONTROLS AND OPERATION

CONTROL FUNCTIONS OVERVIEW

Describes operation of engine stop switch, throttle, clutch, brakes, and starter.

STARTING AND BREAK-IN PROCEDURES

Provides steps for starting the engine, break-in procedures, and fuel recommendations.

MAINTENANCE PROCEDURES

TORQUE-CHECK POINTS

Lists critical points for torque checking after break-in or before each race for safety.

CLEANING AND STORAGE GUIDELINES

Provides instructions for machine cleaning and preventive measures for storage.

VEHICLE SPECIFICATIONS

GENERAL SPECIFICATIONS

Lists general vehicle specifications including dimensions, weight, and engine type.

MAINTENANCE SPECIFICATIONS - ENGINE

Lists maintenance specifications for engine components like cylinder head, cylinder, and camshafts.

MAINTENANCE SPECIFICATIONS - CHASSIS

Lists maintenance specifications for steering, suspension, and brakes.

MAINTENANCE SPECIFICATIONS - ELECTRICAL

Details maintenance specifications for electrical components like ignition and sensors.

TIGHTENING TORQUE SPECIFICATIONS

ENGINE TORQUE VALUES

Lists specific tightening torques for various engine components.

CHASSIS TORQUE VALUES

Lists specific tightening torques for chassis components like brackets and forks.

GENERAL TORQUE SPECIFICATIONS AND UNITS

Specifies torque for standard fasteners and defines units of measurement.

SYSTEM ROUTING AND DIAGRAMS

LUBRICATION DIAGRAMS

Illustrates the lubrication system with numbered components for clarity.

CABLE ROUTING DIAGRAMS

Shows the routing of various cables and hoses on the motorcycle frame.

REGULAR INSPECTION AND MAINTENANCE SCHEDULE

MAINTENANCE INTERVALS OVERVIEW

Provides a schedule for engine, chassis, and electrical maintenance based on usage.

PRE-OPERATION INSPECTION

GENERAL INSPECTION AND MAINTENANCE CHECKLIST

Outlines essential pre-operation checks for coolant, fuel, engine oil, and brakes.

ENGINE SERVICE

COOLING SYSTEM MAINTENANCE

Explains coolant level checks, coolant changes, and radiator cap inspection.

CLUTCH SYSTEM ADJUSTMENTS

Guides on adjusting clutch lever and cable free play for optimal engagement.

THROTTLE AND AIR FILTER SERVICE

Details throttle cable adjustment, lubrication, and air filter cleaning.

ENGINE OIL AND FUEL SYSTEM CHECKS

Covers engine oil level checks, fuel line checks, and throttle body joint inspection.

ENGINE OIL CHANGE AND IDLING ADJUSTMENT

Outlines engine oil change, oil pressure check, and idling speed adjustment.

VALVE CLEARANCE ADJUSTMENT

Provides detailed steps for adjusting valve clearance when the engine is cool.

CHASSIS COMPONENTS SERVICE

BRAKE SYSTEM MAINTENANCE

Explains brake system bleeding, front/rear brake adjustments, and pad replacement.

WHEEL AND DRIVE CHAIN SERVICE

Details checking wheels, spokes, drive chain, and sprocket maintenance.

FRONT FORK SERVICE AND ADJUSTMENT

Guides on front fork removal, disassembly, checks, and damping adjustments.

STEERING SYSTEM MAINTENANCE

Details inspection and removal/installation of steering stem, bearings, and ring nut.

REAR SUSPENSION AND SWINGARM SERVICE

SWINGARM SERVICE

Details swingarm removal, disassembly, and inspection of bearings and oil seals.

REAR SHOCK ABSORBER SERVICE

Provides handling notes, bearing removal, inspection, and installation for the rear shock absorber.

FUEL SYSTEM COMPONENTS

FUEL TANK REMOVAL AND SERVICE

Details fuel tank removal, fuel extraction, pump service, and tank installation.

THROTTLE BODY SERVICE

Covers throttle body removal, disassembly, checks, and replacement of components.

ELECTRICAL SYSTEM OVERVIEW

ELECTRICAL COMPONENTS LISTING

Lists electrical components with corresponding numbers for identification.

WIRING DIAGRAM

Displays the motorcycle's wiring diagram, showing connections between electrical components.

IGNITION SYSTEM INSPECTION

Outlines inspection steps for ignition system failures and spark plug checks.

SENSOR SYSTEM CHECKS

Provides steps for troubleshooting the throttle position sensor and checking input voltage.

FUEL INJECTION SYSTEM DIAGNOSTICS

FI DIAGNOSTIC TOOL OPERATION

Provides instructions for connecting the FI diagnostic tool and checking fault codes.

SENSOR AND SYSTEM TROUBLESHOOTING

Lists sensor operations and troubleshooting steps for various fault codes.

FUEL PUMP SYSTEM INSPECTION

FUEL PUMP INSPECTION STEPS

Provides steps for inspecting the fuel pump if it's not operating normally.

CHASSIS TUNING AND SUSPENSION SETTINGS

SPROCKET SELECTION AND TIRE PRESSURE

Discusses sprocket selection, tire pressure adjustment, and front fork setting factors.

FRONT FORK SUSPENSION SETTINGS

Provides a table for diagnosing and adjusting front fork symptoms like stiffness or bottoming out.

REAR SHOCK ABSORBER SETTINGS

Provides a table for diagnosing and adjusting rear shock absorber symptoms like stiffness or bottoming out.

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