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Yamaha YZ450F 2020 Service Manual

Yamaha YZ450F 2020
370 pages
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B2W-28199-80
OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU PROPRIÉTAIRE
FAHRER- UND WARTUNGSHANDBUCH
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
YZ450F
YZ450FL
Original instructions
Notice originale
Originalbetriebsanleitung
YZ450F
2020
2020
YZ450F YZ450FL
PRINTED IN JAPAN
2019.05-1.3×2 !
(E, F, G)
B2W-28199-80_Hyoshi_27mm.indd 1-3 2019/07/12 15:07:25

Table of Contents

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Yamaha YZ450F 2020 Specifications

General IconGeneral
Bore x Stroke97.0mm x 60.8mm
Compression Ratio13.0:1
IgnitionTCI: Transistor Controlled Ignition
Transmission5-speed
Final DriveChain
Rear SuspensionKYB® single shock; fully adjustable, 12.5-in travel
Front BrakeHydraulic disc, 270mm
Length85.6 in
Width32.5 in
Wheelbase58.5 in
Ground Clearance13.0 in
Fuel Capacity1.6 gal
Wet Weight245 lb
Engine TypeLiquid-cooled DOHC 4-stroke; 4 valves
Fuel DeliveryFuel Injection
Front SuspensionKYB® speed-sensitive system, inverted fork; fully adjustable, 12.2-in travel
Rear BrakeHydraulic disc, 245mm
Front Tire80/100-21
Rear Tire120/80-19

Summary

General Information

Safety Information

Crucial safety guidelines and precautions for operating the vehicle safely.

Location of Important Labels

Identification and explanation of important labels on the vehicle.

Description

Overview of the vehicle's main components and their functions.

Identification

Information on vehicle identification numbers and engine serial numbers.

Included Parts

List and description of parts included with the vehicle.

Important Information

Key notes and preparation steps for maintenance and disassembly.

Basic Service Information

Fundamental information for servicing, including electrical system handling.

Special Tools

List of special tools required for accurate adjustment and assembly.

Instrument and Control Functions

Explanation of various instruments and control functions on the vehicle.

Starting and Break-in

Procedures and precautions for starting the engine and the break-in period.

Maintenance After Break-in

Essential maintenance tasks to perform after the break-in period.

Torque-Check Points

Specifications for tightening torques on various vehicle components.

Motorcycle Care and Storage

Guidelines for cleaning, maintenance, and proper storage of the motorcycle.

Specifications

General Specifications

General dimensions, weight, and capacity details of the vehicle.

Engine Specifications

Detailed technical specifications for the engine, including clearances and capacities.

Chassis Specifications

Technical specifications related to the chassis, wheels, brakes, and suspension.

Electrical Specifications

Technical data for the vehicle's electrical system components.

Tightening Torques

Specifications for tightening torques of standard and special fasteners.

Cable Routing Diagram

Diagrams illustrating the correct routing of cables and hoses on the vehicle.

Periodic Checks and Adjustments

Maintenance Intervals

Schedule for regular maintenance tasks based on usage intervals.

Pre-Operation Inspection and Maintenance

Checks to perform before operating the machine for safety and performance.

Engine

Procedures for checking and adjusting engine components.

Chassis

Checks and adjustments for chassis components like brakes and suspension.

Electrical System

Procedures for checking and maintaining the vehicle's electrical system.

Chassis

General Chassis

Procedures for removing and installing general chassis parts like seat and side cover.

Front Wheel

Detailed procedures for removing, disassembling, checking, and installing the front wheel.

Rear Wheel

Procedures for removing, checking, and installing the rear wheel and sprocket.

Front Brake

Inspection, replacement, and maintenance procedures for the front brake system.

Rear Brake

Inspection, replacement, and maintenance procedures for the rear brake system.

Handlebar

Procedures for removing, checking, and installing the handlebar and its controls.

Front Fork

Steps for removing, disassembling, checking, and assembling the front fork legs.

Steering Head

Procedures for removing, checking, and installing the steering head components.

Rear Shock Absorber Assembly

Handling, removal, checking, and installation of the rear shock absorber.

Swingarm

Procedures for removing, checking, and installing the swingarm.

Chain Drive

Maintenance procedures for the drive chain, sprockets, and related components.

Engine

Lubrication System Chart and Diagrams

Diagrams illustrating the engine's oil lubrication system.

Engine Removal

Step-by-step instructions for removing the engine from the chassis.

Camshaft

Procedures for removing, checking, and installing the camshaft.

Cylinder Head

Steps for removing, checking, and installing the cylinder head.

Valves and Valve Springs

Procedures for removing, checking, and installing valves and related components.

Cylinder and Piston

Procedures for removing, checking, and installing the cylinder and piston.

Generator

Steps for removing, checking, and installing the generator components.

Starter Clutch

Procedures for checking the starter clutch and its components.

Electric Starter

Procedures for removing, disassembling, and assembling the electric starter motor.

Clutch

Steps for removing, checking, and installing the clutch assembly.

Shift Shaft

Procedures for removing, checking, and installing the shift shaft and related parts.

Oil Pump

Steps for removing, checking, and assembling the oil pump components.

Crankcase

Procedures for separating, checking, and assembling the crankcase.

Crankshaft and Balancer Shaft

Steps for removing, checking, and installing the crankshaft and balancer shaft.

Transmission

Procedures for removing, checking, and installing the transmission components.

Cooling System

Cooling System Diagrams

Schematic diagrams illustrating the cooling system layout.

Radiator

Procedures for removing, checking, and installing the radiator.

Water Pump

Steps for removing, checking, and assembling the water pump.

Fuel System

Fuel Tank

Procedures for removing, checking, and installing the fuel tank and pump.

Throttle Body

Steps for checking and adjusting the throttle body and related sensors.

Electrical System

Ignition System

Circuit diagram and troubleshooting for the ignition system.

Electric Starting System

Circuit diagram and troubleshooting for the electric starting system.

Charging System

Circuit diagram and troubleshooting for the charging system.

Fuel Injection System

Circuit diagrams, diagnostic tools, and troubleshooting for the fuel injection system.

Fuel Pump System

Circuit diagram and troubleshooting procedures for the fuel pump system.

Electrical Components

Checking procedures for various electrical components like switches and battery.

Troubleshooting

General Information

General guidance and notes for performing troubleshooting.

Troubleshooting of Engine (Fault Code Not Detected)

Diagnosing engine-related issues when no fault code is present.

Troubleshooting of Clutch

Diagnosing and resolving common clutch-related problems.

Troubleshooting of Transmission

Diagnosing and resolving common transmission issues.

Troubleshooting of Cooling System

Diagnosing and resolving cooling system problems like overheating.

Troubleshooting of Brake

Diagnosing and resolving common brake system issues.

Troubleshooting of Suspension

Diagnosing and resolving common suspension problems.

Troubleshooting of Steering/Handling

Diagnosing and resolving issues related to steering and handling.

Troubleshooting of Charging System

Diagnosing and resolving charging system problems like battery not charging.

Self-Diagnostic Function and Diagnostic Code Table

Reference tables for self-diagnostic functions and fault codes.

Tuning

Chassis

Adjustments for chassis components like sprockets and tire pressure.

Front Fork Setting

Adjusting front fork characteristics including oil amount, preload, and damping.

Rear Suspension Setting

Adjusting rear shock absorber settings like spring preload and damping force.

Wiring Diagram

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