2016
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.
OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
YZ450F
YZ450FG
B11-28199-80
Q
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
Q
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit
être remis avec le véhicule en cas de vente de ce dernier.
Q
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Diese Bedienungsanleitung muss, wenn das Fahrzeug verkauft wird, beim Fahrzeug verbleiben.
Read this manual carefully before operating this vehicle.Read this manual carefully before operating this vehicle.
20152016
OWNER’S SERVICE MANUALOWNER’S SERVICE MANUAL
YZ450FYZ450F
YZ450FG
B11-28199-80-E0
EASB111002
YZ450F
YZ450FG
OWNER’S SERVICE MANUAL
©2015 by Yamaha Motor Co., Ltd.
First edition, March 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
EASB111003
TIP
WARNING
WARNING
NOTICE
TIP
INTRODUCTION
Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s
vast experience in the production of pacesetting racing machines. It represents the highest grade of
craftsmanship and reliability that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If you
have any questions about this manual or your machine, please contact your Yamaha dealer.
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual
contains the most current product information available at the time of printing, there may be minor
discrepancies between your machine and this manual. If you have any questions concerning this
manual, please consult your Yamaha dealer.
EWA
PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A
SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL
YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
EASB111004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
EASB111005
SAFETY INFORMATION
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road
use on public lands may also be illegal. Please check local regulations before riding.
• THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics.
• THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this machine.
• ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an approved helmet with goggles or a face shield. Also
wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not
be caught in any of the moving parts or controls of the machine.
• ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get
into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.
• ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are
poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.
Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope
or soft ground as it may fall over.
• THE ENGINE, EXHAUST PIPE AND MUFFLER WILL BE VERY HOT AFTER THE ENGINE HAS
BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
For safety, drain the gasoline from the fuel tank before transporting the vehicle.
EASB111006
1
7
3
4
6
2
5
HOW TO USE THIS MANUAL
In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment
procedures are laid out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section
title “1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of
each removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a removal or a disassembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, the
names of parts, the notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequentially.
EASB111007
TIP
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New
SYMBOLS
The following symbols are used in this manual for easier understanding.
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Locking agent (LOCTITE®)
Engine oil Replace the part with a new one.
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
1
2
3
4
5
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLESHOOTING
TUNING
6
7
8
9
10
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS............................................................1-1
DESCRIPTION..................................................................................................1-4
IDENTIFICATION .............................................................................................1-5
VEHICLE IDENTIFICATION NUMBER ......................................................1-5
ENGINE SERIAL NUMBER .......................................................................1-5
INCLUDED PARTS ..........................................................................................1-6
SIDESTAND ...............................................................................................1-6
SPARK PLUG WRENCH ...........................................................................1-6
NIPPLE WRENCH......................................................................................1-6
HANDLEBAR PROTECTOR ......................................................................1-6
FUEL HOSE JOINT COVER ......................................................................1-6
COUPLER FOR CONNECTING OPTIONAL PART...................................1-6
IMPORTANT INFORMATION ..........................................................................1-8
PREPARATION FOR REMOVAL AND DISASSEMBLY............................ 1-8
REPLACEMENT PARTS............................................................................1-8
GASKETS, OIL SEALS AND O-RINGS ..................................................... 1-9
LOCK WASHERS/PLATES AND COTTER PINS ......................................1-9
BEARINGS AND OIL SEALS .....................................................................1-9
CIRCLIPS ...................................................................................................1-9
1
BASIC SERVICE INFORMATION..................................................................1-10
ELECTRICAL SYSTEM............................................................................1-10
SPECIAL TOOLS ...........................................................................................1-13
CONTROL FUNCTIONS ................................................................................1-18
ENGINE STOP SWITCH..........................................................................1-18
LAUNCH CONTROL SWITCH .................................................................1-18
CLUTCH LEVER ......................................................................................1-18
SHIFT PEDAL ..........................................................................................1-18
KICKSTARTER LEVER............................................................................1-19
THROTTLE GRIP.....................................................................................1-19
FRONT BRAKE LEVER ...........................................................................1-19
REAR BRAKE PEDAL..............................................................................1-19
STARTER KNOB/IDLE SCREW ..............................................................1-19
FUEL TANK CAP .....................................................................................1-20
STARTING AND BREAK-IN ..........................................................................1-21
FUEL ........................................................................................................1-21
STARTING A COLD ENGINE ..................................................................1-21
STARTING A WARM ENGINE.................................................................1-22
BREAK-IN PROCEDURES ...................................................................... 1-22
MAINTENANCE AFTER BREAK-IN ..............................................................1-23
MAJOR MAINTENANCE..........................................................................1-23
TORQUE-CHECK POINTS ............................................................................1-24
CLEANING AND STORAGE..........................................................................1-26
CLEANING ...............................................................................................1-26
STORAGE ................................................................................................1-26
LOCATION OF IMPORTANT LABELS
9,10,117,8
13
12
1,2,3 4,5,6
EASB111008
LOCATION OF IMPORTANT LABELS
Please read the following important labels carefully before operating this vehicle.
CAN
1-1
LOCATION OF IMPORTANT LABELS
EUR
1-2
AUS, NZL, ZAF
LOCATION OF IMPORTANT LABELS
1-3
EASB111009
TIP
21
7
6
89 10
54 3
12 11 18 17 16 15 14
13
DESCRIPTION
DESCRIPTION
1. Clutch lever 10. Radiator
2. Front brake lever 11. Coolant drain bolt
3. Throttle grip 12. Rear brake pedal
4. Radiator cap 13. Air filter
5. Fuel tank cap 14. Drive chain
6. Launch control switch 15. Shift pedal
7. Engine stop switch 16. Oil level check window
8. Fuel tank 17. Starter knob/idle screw
9. Kickstarter lever 18. Front fork
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have purchased.
1-4
EASB111010
1
1
IDENTIFICATION
There are two significant reasons for knowing
the serial number of your vehicle:
1. When ordering parts, you can give the num-
ber to your Yamaha dealer for positive identification of the model you own.
2. If your vehicle is stolen, the authorities will
need the number to search for and identify
your vehicle.
EASB111011
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is
stamped into the right side of the frame.
IDENTIFICATION
EASB111012
ENGINE SERIAL NUMBER
The engine serial number “1” is stamped into
the elevated part of the right-side of the engine.
1-5
INCLUDED PARTS
WARNING
NOTICE
1
1
a
1
A
A
1
1
EASB111013
INCLUDED PARTS
EASB111014
SIDESTAND
The sidestand “1” is used to support only the
machine when standing or transporting it.
EWA@
• Never apply additional force to the sidestand.
• Remove this sidestand before starting out.
EASB111015
SPARK PLUG WRENCH
The spark plug wrench “1” is used to remove or
install the spark plug.
HANDLEBAR PROTECTOR
Install the handlebar protector “1” with the mark
“a” facing forward.
EASB111018
FUEL HOSE JOINT COVER
The fuel hose joint covers “1” are used to prevent mud, dust, and other foreign materials
from entering the inside when the fuel hose is
disconnected.
EASB111016
NIPPLE WRENCH
The nipple wrench “1” is used to tighten the
spoke.
EASB111017
EASB111019
COUPLER FOR CONNECTING OPTIONAL
PART
The coupler “1” is used for connecting the optional Power Tuner and so on.
ECA
When no optional parts, etc. are connected,
connect the connection terminal to the original coupler.
Before disconnecting the coupler, thoroughly wipe off any mud or water stuck to it.
1-6
Part name Part number
INCLUDED PARTS
GYTR Power Tuner
(For USA)
YZ Power Tuner
(Except for USA)
The Power Tuner is an optional part.
33D-H59C0-V0-00
33D-859C0-10
1-7
EAS20180
WARNING
IMPORTANT INFORMATION
EASB111020
PREPARATION FOR REMOVAL AND DISASSEMBLY
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the entry of them into the inside during the jobs.
• Before cleaning with high-pressure water of
washers, cover the following parts.
Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Hole under the water pump housing
IMPORTANT INFORMATION
4. During disassembly, clean each of the parts,
and store them in trays for each section.
5. Flammable. Keep servicing areas away
from any source of fire.
6. During servicing, take special care not to receive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore,
rinse it out with water in good time.
EWA
Coolant is potentially harmful and should
be handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
2. Use proper special tools and equipment.
See “SPECIAL TOOLS”.
3. During disassembly, check and measure the
required parts, and make a record of them
so that you may refer to the record when installing them. Moreover, arrange gears, cylinders, pistons, and other parts for each
section so as not to confuse or lose them.
EASB111021
REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
used for repair of the vehicle, including periodic
replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar appearances or because the quality may be
changed by aging.
1-8
IMPORTANT INFORMATION
NOTICE
EASB111022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets and O-rings. All gasket surfaces, oil
seal lips, and O-rings must be cleaned so
that there may be no dust on them.
2. During assembly, always apply proper oil to
bearings and proper grease to oil seal lips
before installation.
1. Oil
2. Lip
3. Spring
4. Grease
EASB111023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace lock washers/plates “1”
and cotter pins with new ones. After the bolt or
nut has been tightened to specification, firmly
bend the lock tabs along a flat of the bolt or nut.
EASB111024
BEARINGS AND OIL SEALS
Install bearings “1” and oil seals “2” with their
manufacturer’s marks or size symbols facing
outward. During installation of an oil seal, make
sure that its main lip faces the oil chamber (the
target to be sealed). Before installation, always
apply a light coat of grease to the oil seal lip.
ECA
Do not spin the bearing with compressed air
because this will damage the bearing surfaces.
EASB111025
CIRCLIPS
When assembling parts, always use new circlips. During installation of a circlip, make sure
that the edge “2” of the circlip “1” is positioned
opposite to the force “3” that the circlip receives. Install the circlip with its end aligned
with the center of the spline, without opening
the circlip more than necessary.
1-9
BASIC SERVICE INFORMATION
NOTICE
NOTICE
NOTICE
NOTICE
a
EASB111026
BASIC SERVICE INFORMATION
EASB111027
ELECTRICAL SYSTEM
Electrical parts handling
ECA16620
Handle electrical components with special
care, and do not subject them to strong
shocks.
ECA16630
Electrical components are very sensitive to
and can be damaged by static electricity.
Therefore, never touch the terminals and be
sure to keep the contacts clean.
Checking the electrical system
ECA14371
Never insert the tester probes into the coupler terminal slots. Always insert the probes
from the opposite end “a” of the coupler,
taking care not to loosen or damage the
leads.
ECA16640
For waterproof couplers, never insert the
tester probes directly into the coupler.
When performing any checks using a waterproof coupler, use the specified test harness or a suitable commercially available
test harness.
1-10
BASIC SERVICE INFORMATION
NOTICE
NOTICE
TIP
1
Checking the connections
Check leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• Lead
• Coupler
• Connector
ECA16780
• When disconnecting a coupler, release the
coupler lock, hold both sections of the
coupler, and then disconnect the coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of coupler lock before disconnecting the coupler.
ECA16790
2. Check:
• Lead
• Coupler
• Connector
Moisture Dry with compressed air.
Rust/stains Connect and disconnect several times.
3. Check:
• All connections
Loose connection Connect properly.
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling or assembling a coupler,
pull on the leads to make sure that they are installed securely.
When disconnecting a connector, do not
pull the leads. Hold both sections of the
connector, and then disconnect the connector.
1-11
BASIC SERVICE INFORMATION
TIP
TIP
4. Connect:
• Lead
• Coupler
• Connector
• When connecting a coupler or a connector,
make sure that both terminals are connected
securely.
• Make sure all connections are tight.
5. Check:
• No continuity
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (4).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-12
SPECIAL TOOLS
TIP
EASB111028
SPECIAL TOOLS
The following special tools are required for accurate and complete adjustment and assembly. Using
the correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and tool number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.
• For U.S.A. and Canada, use tool number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use tool number starting with “90890-”.
Tool name/Part number How to use Illustration
Dial gauge & stand set
90890-01252
Dial gauge set
YU-03097-B
This tool is used to check
parts for runout or bend.
Crankshaft installer pot
90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolts
YU-90060
Adapter (M12)
90890-01278
Adapter #3
YU-90063
This tool is used to install the
crankshaft.
This tool is used to install the
crankshaft.
This tool is used to install the
crankshaft.
Piston pin puller set
90890-01304
Piston pin puller
YU-01304
This tool is used to remove
the piston pin.
1-13
SPECIAL TOOLS
Tool name/Part number How to use Illustration
Radiator cap tester
90890-01325
Mityvac cooling system tester
kit
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
This tool is used to check the
radiator and the radiator cap.
This tool is used to check the
radiator and the radiator cap.
This tool is used to remove or
tighten the steering nut.
Cap bolt wrench
90890-01500
YM-01500
Cap bolt ring wrench
90890-01501
YM-01501
Fork seal driver
90890-01502
YM-A0948
Spoke nipple wrench (6–7)
90890-01521
YM-01521
This tool is used to remove or
tighten the base valve.
This tool is used to loosen or
tighten the damper assembly.
This tool is used to install the
oil seal of the front fork.
This tool is used to tighten the
spoke.
1-14
SPECIAL TOOLS
Tool name/Part number How to use Illustration
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Timing light
90890-03141
YU-03141
Pressure gauge
90890-03153
YU-03153
Fuel pressure adapter
90890-03186
YM-03186
This tool is used to measure
the voltage, current, and resistance of electrical components.
This tool is used to measure
the ignition timing.
This tool is used to measure
the fuel pressure.
This tool is used to mount the
pressure gauge.
Test harness S-pressure
sensor (3P)
90890-03207
YU-03207
FI diagnostic tool sub-lead
90890-03212
YU-03212
Yamaha diagnostic tool
90890-03231
Yamaha diagnostic tool (US)
90890-03234
Valve guide remover & installer set (ø5.5)
90890-04016
Valve guide remover (5.5
mm)
YM-01122
Valve guide installer (5.5
mm)
YM-04015
Valve guide reamer (5.5 mm)
YM-01196
This tool is used to check the
throttle position sensor input
voltage.
This tool is used to connect
the Yamaha diagnostic tool
to a battery.
This tool is used to check error codes or carry out self-diagnosis.
This tool is used to replace
the valve guide.
1-15
SPECIAL TOOLS
YM-04019
YM-91044
Tool name/Part number How to use Illustration
Valve spring compressor
90890-04019
YM-04019
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
Clutch holder
90890-04086
YM-91042
This tool is used to disconnect or connect the valve and
the valve spring.
This tool is used to install the
crankshaft.
This tool is used to hold the
clutch when removing or installing the clutch boss securing nut.
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
Valve spring compressor
adapter 22 mm
90890-04108
YM-04108
Rotor puller
90890-04151
YM-04151
This tool is used to remove
the valve lifter or lap the
valve.
This tool is used to disconnect or connect the valve and
the valve spring.
This tool is used to remove
the rotor.
1-16
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