Yamaha YZ450FN 2022 Motocross Motorcycle Manuals

Manuals and User Guides for Yamaha YZ450FN 2022 Motocross Motorcycle. We have 1 Yamaha YZ450FN 2022 Motocross Motorcycle manual available for free PDF download: Owner's Service Manual

Yamaha YZ450FN 2022 Owner's Service Manual

Yamaha YZ450FN 2022 Owner's Service Manual (366 pages)

Brand: Yamaha | Category: Motorcycle | Size: 22.63 MB

Table of Contents

Table of Contents

9
- Safety Information
  13
- For Safety, be Sure to Obey the Following
  13
- Location of Important Labels
  16
- Description
  17
- Identification
  18
- Vehicle Identification Number
  18
- Engine Serial Number
  18
- Power Tuner
  19
- Fuel Hose Joint Cover
  19
- Nipple Wrench
  19
- Handlebar Protector
  19
- Sidestand
  19
- Included Parts
  19
- Important Information
  21
- Preparation for Removal and Disassembly
  21
- Replacement Parts
  21
- Gaskets, Oil Seals and O-Rings
  21
- Lock Washers/Plates and Cotter Pins
  22
- Bearings and Oil Seals
  22
- Circlips
  22
- Basic Service Information
  23
- Electrical System
  23
- Special Tools
  27
- Instrument and Control Functions
  33
- Engine Stop Switch
  33
- Start Switch
  33
- Launch Control Switch
  33
- Mode Switch
  33
- Rear Brake Pedal
  34
- Starter Knob
  34
- Front Brake Lever
  34
- Shift Pedal
  34
- Fuel Tank Cap
  35
- Starting and Break-In
  36
- Fuel
  36
- Starting a Cold Engine
  36
- Starting a Warm Engine
  37
- Break-In Procedures
  37
- Engine Starting Precaution
  37
- Maintenance after Break-In
  38
- Major Maintenance
  38
- Air Filter Maintenance
  38
- Torque-Check Points
  39
- Motorcycle Care and Storage
  41
- Care
  41
- Storage
  42
Specifications

45
- General Specifications
  46
- Engine Specifications
  47
- Chassis Specifications
  52
- Electrical Specifications
  53
- General Tightening Torque Specifications
  54
- Tightening Torques
  54
- Engine Tightening Torques
  55
- Chassis Tightening Torques
  58
- Cable Routing Diagram
  62
Periodic Checks and Adjustments

75
- Maintenance Intervals
  77
- General Inspection and Maintenance
  81
- Pre-Operation Inspection and Maintenance
  81
- Adjusting the Valve Clearance
  82
- Engine
  82
- Valve Clearance Shim Chart
  85
- Checking the Engine Idling Speed
  87
- Checking the Throttle Grip
  87
- Checking the Spark Plug
  88
- Changing the Engine Oil
  89
- Checking the Engine Oil Level
  89
- Adjusting the Clutch Lever Free Play
  91
- Adjusting the Clutch Lever Position
  91
- Cleaning the Air Filter Element
  91
- Checking the Fuel Line
  93
- Checking the Throttle Body Joint
  93
- Checking the Cylinder Head Breather Hose
  94
- Checking the Exhaust System
  94
- Checking the Coolant Level
  96
- Changing the Coolant
  97
- Checking the Cooling System
  97
- Adjusting the Front Disc Brake
  99
- Adjusting the Rear Disc Brake
  99
- Chassis
  99
- Checking the Brake Fluid Level
  99
- Checking the Front Brake Hose
  100
- Checking the Front Brake Pads
  100
- Checking the Rear Brake Hose
  100
- Checking the Rear Brake Pads
  100
- Bleeding the Hydraulic Brake System
  101
- Checking the Brake Operation
  101
- Drive Chain Slack
  102
- Checking and Adjusting the Steering Head
  103
- Lubricating the Steering Head
  103
- Adjusting the Front Fork Legs
  104
- Checking the Front Fork Legs
  104
- Adjusting the Rear Shock Absorber Assembly
  106
- Checking the Rear Shock Absorber Assembly
  106
- Checking the Connecting Arm and Relay Arm
  108
- Checking the Swingarm Operation
  108
- Checking the Tires
  108
- Lubricating the Swingarm Pivot
  108
- Checking and Lubricating the Cables
  109
- Checking and Tightening the Spokes
  109
- Checking the Chassis Fasteners
  109
- Checking the Wheel Bearings
  109
- Checking the Wheels
  109
- Lubricating the Brake Lever
  110
- Lubricating the Clutch Lever
  110
- Lubricating the Pedal
  110
- Checking and Charging the Battery
  111
- Checking the Fuses
  111
- Checking the Ignition Timing
  111
- Electrical System
  111
Chassis

113
- General Chassis
  117
- Installing the Air Scoop
  117
- Removing the Number Plate
  117
- Removing the Seat
  117
- Installing the Side Cover
  118
- Removing the Side Cover
  118
- Front Wheel
  119
- Assembling the Front Wheel
  120
- Checking the Front Wheel
  120
- Disassembling the Front Wheel
  120
- Removing the Front Wheel
  120
- Installing the Front Wheel
  121
- Rear Wheel
  123
- Checking and Replacing the Rear Wheel Sprocket
  124
- Checking the Rear Wheel
  124
- Disassembling the Rear Wheel
  124
- Removing the Rear Wheel
  124
- Assembling the Rear Wheel
  125
- Installing the Rear Wheel
  125
- Front Brake
  128
- Checking the Front Brake Disc
  131
- Introduction
  131
- Replacing the Front Brake Pads
  131
- Assembling the Front Brake Caliper
  133
- Checking the Front Brake Caliper
  133
- Disassembling the Front Brake Caliper
  133
- Removing the Front Brake Caliper
  133
- Installing the Front Brake Caliper
  134
- Assembling the Front Brake Master Cylinder
  135
- Checking the Front Brake Master Cylinder
  135
- Removing the Front Brake Master Cylinder
  135
- Installing the Front Brake Master Cylinder
  136
- Rear Brake
  138
- Checking the Rear Brake Disc
  142
- Introduction
  142
- Replacing the Rear Brake Pads
  142
- Checking the Rear Brake Caliper
  144
- Disassembling the Rear Brake Caliper
  144
- Removing the Rear Brake Caliper
  144
- Assembling the Rear Brake Caliper
  145
- Installing the Rear Brake Caliper
  145
- Assembling the Rear Brake Master Cylinder
  146
- Checking the Rear Brake Master Cylinder
  146
- Removing the Rear Brake Master Cylinder
  146
- Installing the Rear Brake Master Cylinder
  147
- Checking the Handlebar
  151
- Installing the Handlebar
  151
- Removing the Handlebar
  151
- Front Fork
  156
- Disassembling the Front Fork Legs
  158
- Removing the Front Fork Legs
  158
- Checking the Front Fork Legs
  159
- Assembling the Front Fork Legs
  160
- Installing the Front Fork Legs
  167
- Steering Head
  169
- Checking the Steering Head
  170
- Installing the Steering Head
  170
- Removing the Lower Bracket
  170
- Rear Shock Absorber Assembly
  173
- Checking the Rear Shock Absorber Assembly
  176
- Disposing of a Rear Shock Absorber
  176
- Handling the Rear Shock Absorber
  176
- Removing the Rear Shock Absorber Assembly
  176
- Checking the Connecting Arm and Relay Arm
  177
- Installing the Rear Shock Absorber Assembly
  177
- Installing the Relay Arm
  177
- Swingarm
  179
- Checking the Swingarm
  180
- Installing the Swingarm
  180
- Removing the Swingarm
  180
- Chain Drive
  182
- Checking the Drive Chain
  183
- Removing the Drive Chain
  183
- Checking the Drive Sprocket
  184
- Checking the Rear Wheel Sprocket
  184
- Installing the Drive Chain
  184
Engine

185
- Engine Oil Lubrication Chart
  187
- Lubrication System Chart and Diagrams
  187
- Lubrication Diagrams
  188
- Engine Removal
  192
- Installing the Engine
  196
- Removing the Engine
  196
- Installing the Exhaust Pipe and Muffler
  197
- Camshaft
  199
- Removing the Camshaft
  201
- Checking the Camshaft
  202
- Checking the Decompression System
  203
- Checking the Timing Chain and Camshaft Sprocket
  203
- Checking the Timing Chain Tensioners
  203
- Installing the Camshafts
  203
- Cylinder Head
  206
- Checking the Cylinder Head
  208
- Checking the Timing Chain Guide (Intake Side)
  208
- Installing the Cylinder Head
  208
- Removing the Cylinder Head
  208
- Removing the Valves
  212
- Valves and Valve Springs
  212
- Checking the Valves and Valve Guides
  213
- Checking the Valve Seats
  214
- Checking the Valve Springs
  215
- Checking the Valve Lifters
  216
- Installing the Valves
  216
- Cylinder and Piston
  218
- Checking the Cylinder and Piston
  219
- Removing the Piston
  219
- Checking the Piston Rings
  220
- Checking the Piston Pin
  221
- Installing the Piston and Cylinder
  221
- Generator
  223
- Checking the Generator
  224
- Checking the Woodruff Key
  224
- Installing the Generator
  224
- Removing the Generator
  224
- Starter Clutch
  226
- Checking the Starter Clutch
  227
- Electric Starter
  228
- Assembling the Starter Motor
  230
- Checking the Starter Motor
  230
- Checking the Clutch Boss
  235
- Checking the Clutch Housing
  235
- Checking the Clutch Plates
  235
- Checking the Clutch Springs
  235
- Checking the Friction Plates
  235
- Removing the Clutch
  235
- Checking the Pressure Plate
  236
- Checking the Primary Drive Gear
  236
- Checking the Primary Driven Gear
  236
- Checking the Push Lever Shaft
  236
- Checking the Push Rods
  236
- Installing the Clutch
  236
- Shift Shaft
  240
- Checking the Shift Shaft
  241
- Checking the Stopper Lever
  241
- Installing the Shift Shaft
  241
- Removing the Segment
  241
- Oil Pump
  244
- Assembling the Oil Pump
  246
- Checking the Oil Pump
  246
- Removing the Balancer
  246
- Installing the Oil Pump
  247
- Crankcase
  249
- Checking the Crankcase
  251
- Checking the Timing Chain Guide (Exhaust Side)
  251
- Disassembling the Crankcase
  251
- Assembling the Crankcase
  252
- Crankshaft and Balancer Shaft
  253
- Checking the Crankshaft
  254
- Removing the Crankshaft
  254
- Installing the Crankshaft
  255
- Transmission
  256
- Checking the Shift Drum Assembly
  257
- Checking the Shift Forks
  257
- Checking the Transmission
  257
- Removing the Transmission
  257
- Installing the Transmission
  258
Cooling System

261
- Cooling System Diagrams
  262
- Radiator
  263
- Checking the Radiator
  265
- Installing the Radiator
  265
- Water Pump
  267
- Assembling the Water Pump
  268
- Checking the Water Pump
  268
- Disassembling the Water Pump
  268
Fuel System

271
- Fuel Tank
  272
- Checking the Fuel Pump Body
  273
- Checking the Fuel Pump Operation
  273
- Installing the Fuel Pump
  273
- Removing the Fuel Pump
  273
- Removing the Fuel Tank
  273
- Installing the Fuel Tank
  274
- Throttle Body
  275
- Checking the Fuel Pressure
  278
- Checking the Injector
  278
- Checking the Throttle Body
  278
- Adjusting the Throttle Position Sensor
  279
Electrical System

281
- Circuit Diagram
  282
- Ignition System
  282
- Troubleshooting
  284
- Circuit Diagram
  288
- Electric Starting System
  288
- Troubleshooting
  290
- Charging System
  292
- Circuit Diagram
  292
- Troubleshooting
  294
- Circuit Diagram
  296
- Fuel Injection System
  296
- Connecting the Yamaha Diagnostic Tool
  298
- Yamaha Diagnostic Tool
  298
- Troubleshooting Details (Fault Code)
  300
- Circuit Diagram
  320
- Fuel Pump System
  320
- Troubleshooting
  322
- Electrical Components
  323
- Checking the Switches
  324
- Checking and Charging the Battery
  326
- Checking the Fuses
  326
- Checking the Relay Unit (Diode)
  328
- Checking the Relays
  328
- Checking the Ignition Spark Gap
  329
- Checking the Spark Plug Cap
  329
- Checking the Crankshaft Position Sensor
  330
- Checking the Ignition Coil
  330
- Checking the Lean Angle Sensor
  331
- Checking the Rectifier/Regulator
  331
- Checking the Starter Motor Operation
  331
- Checking the Stator Coil
  331
- Checking the Coolant Temperature Sensor
  332
- Checking the Intake Air Temperature Sensor
  333
- Checking the Throttle Position Sensor Input Voltage
  333
- Checking the Gear Position Switch
  334
- Checking the Injector
  334
Troubleshooting

335
Tuning

351
- Chassis
  352
- Selection of the Secondary Reduction Ratio (Sprocket)
  352
- Tire Pressure
  352
- Change in Amount and Characteristics of Fork Oil
  353
- Front Fork Setting
  353
- Setting of Spring after Replacement
  353
- Choosing Set Length
  354
- Front Fork Setting Parts
  354
- Rear Suspension Setting
  354
- Rear Shock Absorber Setting Parts
  355
- Setting of Spring after Replacement
  355
- Suspension Setting (Front Fork)
  357
- Suspension Setting (Rear Shock Absorber)
  358

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