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YZ450FF 1SL-28199-11
Yamaha YZ450FF 1SL-28199-11 Manuals
Manuals and User Guides for Yamaha YZ450FF 1SL-28199-11. We have
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Yamaha YZ450FF 1SL-28199-11 manual available for free PDF download: Owner's Service Manual
Yamaha YZ450FF 1SL-28199-11 Owner's Service Manual (358 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 11.51 MB
Table of Contents
Table of Contents
9
General Information
11
Location of Important Labels
13
Description
14
Identification
15
Engine Serial Number
15
Model Label
15
Vehicle Identification Number
15
Features
16
Outline of the Fi System
16
Fi System
17
Handlebar Protector
18
Coupler for Connecting Optional Part
18
Fuel Hose Joint Cover
18
Spark Plug Wrench
18
Nipple Wrench
18
Included Parts
18
Sidestand
18
Important Information
20
Preparation for Removal and Disassembly
20
Replacement Parts
20
Bearings and Oil Seals
21
Circlips
21
Gaskets, Oil Seals and O-Rings
21
Lock Washers/Plates and Cotter Pins
21
Basic Service Information
22
Electrical System
22
Special Tools
25
Control Functions
30
Engine Stop Switch
30
Clutch Lever
30
Shift Pedal
30
Kickstarter Lever
30
Throttle Grip
30
Front Brake Lever
30
Fuel Tank Cap
31
Rear Brake Pedal
31
Starter Knob/Idle Screw
31
Starting and Break-In
32
Fuel
32
Starting a Cold Engine
32
Starting a Warm Engine
33
Break-In Procedures
33
Maintenance after Break-In
34
Major Maintenance
34
Torque-Check Points
36
Storage
37
Cleaning
37
Cleaning and Storage
37
Specifications
39
General Specifications
40
Engine Specifications
41
Chassis Specifications
50
Electrical Specifications
51
General Tightening Torque Specifications
52
Tightening Torques
52
Engine Tightening Torques
53
Chassis Tightening Torques
57
Engine
60
Lubrication Points and Lubricant Types
60
Chassis
62
Lubrication Diagrams
64
Lubrication System Chart and Diagrams
64
Cable Routing Diagram
72
Periodic Checks and Adjustments
83
Maintenance Intervals
85
General Inspection and Maintenance
91
Pre-Operation Inspection and Maintenance
91
Changing the Coolant
92
Checking the Coolant Level
92
Checking the Cooling System
92
Engine
92
Checking the Radiator Cap
93
Checking the Radiator Cap Opening Pressure
93
Adjusting the Clutch Lever Position
94
Checking the Coolant Circulatory System for Leaks
94
Adjusting the Clutch Lever Free Play
95
Adjusting the Throttle Grip Free Play
95
Cleaning the Air Filter Element
96
Lubricating the Throttle Cable
96
Checking the Breather Hoses
97
Checking the Throttle Body Joint
97
Checking the Engine Oil Level
98
Checking the Exhaust System
98
Checking the Fuel Line
98
Changing the Engine Oil
99
Adjusting the Engine Idling Speed
100
Adjusting the Valve Clearance
101
Bleeding the Brake System
105
Chassis
105
Adjusting the Front Brake
106
Checking the Brake Hose
106
Adjusting the Rear Brake
107
Checking the Front Brake Pads
107
Checking the Rear Brake Pads
109
Checking the Brake Fluid Level
110
Checking the Rear Brake Pad Insulator
110
Adjusting the Drive Chain Slack
111
Checking the Front Fork Legs
112
Checking the Front Fork Protector Guide
112
Cleaning the Front Fork Oil Seal and Dust Seal
112
Adjusting the Front Fork Legs
113
Air Bleeding from Front Fork
113
Adjusting the Rear Shock Absorber Assembly
114
Checking the Rear Suspension
114
Checking the Swingarm Operation
114
Checking and Tightening the Spokes
117
Checking the Tires
117
Checking the Wheel Bearings
117
Checking the Wheels
117
Checking and Adjusting the Steering Head
118
Lubricating the Levers
119
Lubricating the Pedal
119
Checking the Ignition Timing
120
Checking the Spark Plug
120
Electrical System
120
Chassis
123
General Chassis
125
Removing the Left Side Cover
126
Removing the Number Plate
126
Removing the Seat
126
Checking the Front Wheel
128
Front Wheel
128
Removing the Front Wheel
128
Assembling the Front Wheel
129
Disassembling the Front Wheel
129
Installing the Front Wheel
130
Checking and Replacing the Rear Wheel Sprocket
132
Checking the Rear Wheel
132
Disassembling the Rear Wheel
132
Rear Wheel
132
Removing the Rear Wheel
132
Assembling the Rear Wheel
133
Installing the Rear Wheel
134
Front Brake
136
Checking the Front Brake Disc
140
Disassembling the Front Brake Caliper
140
Introduction
140
Removing the Front Brake Caliper
140
Assembling the Front Brake Caliper
141
Checking the Front Brake Caliper
141
Installing the Brake Caliper Piston
141
Installing the Front Brake Caliper
142
Assembling the Front Brake Master Cylinder
143
Checking the Front Brake Master Cylinder
143
Removing the Front Brake Master Cylinder
143
Installing the Front Brake Master Cylinder
144
Rear Brake
146
Checking the Rear Brake Disc
150
Introduction
150
Assembling the Rear Brake Caliper
151
Checking the Rear Brake Caliper
151
Disassembling the Rear Brake Caliper
151
Removing the Rear Brake Caliper
151
Installing the Brake Caliper Piston
152
Installing the Rear Brake Caliper
152
Checking the Rear Brake Master Cylinder
153
Removing the Rear Brake Master Cylinder
153
Assembling the Rear Brake Master Cylinder
154
Installing the Rear Brake Master Cylinder
154
Checking the Handlebar
158
Handlebar
158
Installing the Handlebar
158
Removing the Handlebar
158
Front Fork
162
Disassembling the Front Fork Legs
164
Removing 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
Checking the Steering Head
176
Installing the Steering Head
176
Removing the Lower Bracket
176
Rear Shock Absorber Assembly
179
Disposing of a Rear Shock Absorber
182
Handling the Rear Shock Absorber
182
Removing the Rear Shock Absorber Assembly
182
Checking the Connecting Arm and Relay Arm
183
Checking the Rear Shock Absorber Assembly
183
Installing the Relay Arm
183
Removing the Bearing
183
Installing the Rear Shock Absorber Assembly
184
Swingarm
186
Checking the Swingarm
187
Removing the Bearing
187
Removing the Swingarm
187
Installing the Swingarm
188
Chain Drive
189
Checking the Drive Chain
190
Removing 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
Checking the Cylinder Head
217
Checking the Timing Chain Guide (Intake Side)
217
Removing the Cylinder Head
217
Installing the Cylinder Head
218
Checking the Valves and Valve Guides
222
Valves and Valve Springs
222
Checking the Valve Seats
223
Checking the Valve Springs
225
Checking the Valve Lifters
226
Installing the Valves
226
Checking the Cylinder and Piston
229
Cylinder and Piston
229
Removing the Piston
229
Checking the Piston Rings
230
Checking the Piston Pin
231
Installing the Piston and Cylinder
231
Clutch
234
Checking the Clutch Plates
236
Checking the Clutch Springs
236
Checking the Friction Plates
236
Removing the Clutch
236
Checking the Clutch Boss
237
Checking the Clutch Housing
237
Checking the Clutch Push Rods
237
Checking the Pressure Plate
237
Checking the Primary Drive Gear
237
Checking the Push Lever Shaft
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
Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
243
Checking the Kick Shaft and Ratchet Wheel
243
Installing the Kick Shaft Assembly
243
Kickstater
243
Removing the Kick Shaft Assembly
243
Installing the Kick Idle Gear
244
Shift Shaft
245
Checking the Shift Guide and Shift Lever Assembly
247
Checking the Shift Shaft
247
Checking the Stopper Lever
247
Removing the Segment
247
Removing the Shift Guide and Shift Lever Assembly
247
Installing the Segment
248
Installing the Shift Guide and Shift Lever Assembly
248
Installing the Stopper Lever
248
Installing the Shift Pedal
249
Installing the Shift Shaft
249
Oil Pump and Balancer Gear
251
Checking the Balancer
252
Checking the Oil Pump
252
Checking the Primary Drive Gear, Balancer Shaft Drive Gear, and Balancer Weight Gear
252
Removing the Balancer
252
Assembling the Oil Pump
253
Installing the Oil Pump and Balancer Gear
253
Ac Magneto
255
Checking the Ac Magneto
256
Checking the Woodruff Key
256
Installing the Ac Magneto
256
Removing the Ac Magneto
256
Crankcase
259
Checking the Timing Chain, Timing Chain Guide, Oil Strainer
261
Disassembling the Crankcase
261
Removing the Crankcase Bearing
261
Assembling the Crankcase
262
Checking the Crankcase
262
Crankshaft Assembly and Balancer Shaft
263
Checking the Crankshaft Assembly
264
Removing the Balancer Shaft
264
Removing the Crankshaft Assembly
264
Installing the Crankshaft Assembly
265
Checking the Shift Forks
267
Removing the Transmission
267
Transmission
267
Checking the Shift Drum Assembly
268
Checking the Transmission
268
Installing the Transmission
268
Cooling System
271
Fuel System
279
Fuel Tank
280
Checking the Fuel Pump Body
281
Installing the Fuel Pump
281
Removing the Fuel Pump
281
Removing the Fuel Tank
281
Checking the Fuel Pressure
282
Installing the Fuel Tank
282
Checking the Damper
283
Throttle Body
284
Checking the Injector
287
Checking the Throttle Body
287
Checking the Throttle Body Joint
287
Adjusting the Throttle Position Sensor
288
Electrical System
289
Circuit Diagram
292
Ignition System
292
Troubleshooting
294
Charging System
296
Circuit Diagram
296
Troubleshooting
298
Circuit Diagram
300
Fuel Injection System
300
Yamaha Diagnostic Tool
302
Troubleshooting Details
303
Circuit Diagram
322
Fuel Pump System
322
Troubleshooting
324
Electrical Components
326
Checking the Switches
328
Checking the Ignition Coil
331
Checking the Ignition Spark Gap
331
Checking the Spark Plug Cap
331
Checking the Crankshaft Position Sensor
332
Checking the Ecu
332
Checking the Stator Coil
332
Checking the Coolant Temperature Sensor
333
Checking the Rectifier/Regulator
333
Checking the Throttle Position Sensor
334
Checking the Intake Air Pressure Sensor
335
Checking the Intake Air Temperature Sensor
335
Checking the Throttle Position Sensor Input Voltage
335
Checking the Fuel Injector
336
Checking the Neutral Switch
336
Troubleshooting
337
General Information
338
Incorrect Engine Idling Speed
338
Starting Failures
338
Troubleshooting
338
Faulty Clutch
339
Faulty Gear Shifting
339
Jumps out of Gear
339
Overheating
339
Poor Medium-And-High-Speed Performance
339
Shift Pedal Does Not Move
339
Faulty Front Fork Legs
340
Overcooling
340
Poor Braking Performance
340
Unstable Handling
340
List of Self-Diagnostic and Fail-Safe Actions
342
Tuning
345
Chassis
346
Drive and Rear Wheel Sprockets Setting Parts
346
Selection of the Secondary Reduction Ratio (Sprocket)
346
Change in Amount and Characteristics of Fork Oil
347
Front Fork Setting
347
Tire Pressure
347
Choosing Set Length
348
Front Fork Setting Parts
348
Rear Suspension Setting
348
Setting of Spring after Replacement
348
Setting of Spring after Replacement
349
Rear Shock Absorber Setting Parts
350
Suspension Setting (Front Fork)
351
Suspension Setting (Rear Shock Absorber)
352
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