2009 YAMAHA YZ450F stop start

5-26
HANDLEBAR
5. Install:
•Right grip "1"
•Collar "2"
Apply the adhesive on the tube
guide "3".
• Before applying the adhesive, wipe
off grease or oil on the tube guide
surface "a" with a lacquer thinner.
• Install the grip to the tube guide so
that the grip match mark "b" and
tube guide slot "c" form the angle as
shown.
6. Install:
•Collar "1"
• Grip cap cover "2"
• Throttle grip "3"
Apply the lithium soap base grease
on the throttle grip sliding surface.
7. Install:
• Throttle cables "1"
To tube guide "2".
Apply the lithium soap base grease
on the throttle cable end and tube
guide cable winding portion.
8. Install:
• Throttle cable cap "1"
• Screw (throttle cable cap) "2"
After tightening the screws, check
that the throttle grip "3" moves
smoothly. If it does not, retighten
the bolts for adjustment.
9. Install:
• Grip cap cover "1"
• Cover (throttle cable cap) "2"
10. Install:
• Brake master cylinder "1"
• Brake master cylinder bracket "2"
• Bolt (brake master cylinder brack-
et) "3"
• Install the bracket so that the arrow
mark "a" faces upward.
• First tighten the bolt on the upper
side of the brake master cylinder
bracket, and then tighten the bolt on
the lower side.
11. Install:
• Engine stop switch "1"
• Clutch lever holder "2"
• Bolt (clutch lever holder) "3"
• Hot starter lever holder "4"
• Bolt (hot starter lever holder) "5"
•Clamp "6"
• The engine stop switch, clutch lever
holder and clamp should be in-
stalled according to the dimensions
shown.
• Pass the engine stop switch lead in
the middle of the clutch lever hold-
er.
Screw (throttle cable
cap):
4 Nm (0.4 m•kg, 2.9
ft•lb)
Bolt (brake master cylin-
der bracket):
9 Nm (0.9 m•kg, 6.5
ft•lb)
Bolt (clutch lever holder):
5 Nm (0.5 m•kg, 3.6
ft•lb)
Bolt (hot starter lever
holder):
4 Nm (0.4 m•kg, 2.9
ft•lb)

6-4
IGNITION SYSTEM
SPARK GAP TEST
1. Disconnect the ignition coil from
spark plug.
2. Remove the ignition coil cap.
3. Connect the dynamic spark tester
"1" (ignition checker "2") as
shown.
• Ignition coil "3"
• Spark plug "4"
A. For USA and CDN
B. Except for USA and CDN
4. Kick the kickstarter crank.
5. Check the ignition spark gap.
6. Start engine, and increase spark
gap until misfire occurs. (for USA
and CDN only)
CHECKING THE COUPLERS,
LEADS AND IGNITION COIL
CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
• Ignition coil and spark plug as
they are fitted
Push in the ignition coil until it
closely contacts the spark plug
hole in the cylinder head cover.
CHECKING THE ENGINE STOP
SWITCH
1. Inspect:
• Engine stop switch conductionNot conductive while it is pushed→
Replace.
Conductive while it is freed→Re-
place.
Set the tester selection position to "Ω
× 1".
CHECKING THE IGNITION COIL
1. Remove the ignition coil cap.
2. Inspect:
• Primary coil resistance
Out of specification→Replace.
3. Inspect:
• Secondary coil resistance
Out of specification→Replace.4. Inspect:
• Sealed portion of ignition coil "a"
• Spark plug terminal pin "b"
• Threaded portion of spark plug "c"
Wear →Replace.
CHECKING THE CDI MAGNETO
1. Inspect:
• Pickup coil resistance
Out of specification→Replace.
2. Inspect:
• Charging coil 1 resistance
Out of specification→Replace. Minimum spark gap:
6.0 mm (0.24 in)
Tester (+) lead→Black/White lead
"1"
Tester (-) lead→Black lead "2"
Result
Conductive (while the
engine stop switch is
pushed)
Tester (+) lead→Orange lead "1"
Tester (-) lead→Black lead "2"
Primary
coil resis-
tanceTester se-
lector posi-
tion
0.08–0.10
Ω at 20 °C
(68 °F) Ω × 1
Tester (+) lead→Orange lead "1"
Tester (-) lead→Spark plug termi-
nal "2"
Secondary
coil resis-
tanceTester se-
lector posi-
tion
4.6–6.8
kΩat 20 °C
(68 °F) kΩ × 1
Tester (+) lead→Red lead "1"
Tester (-) lead→White lead "2"
Pickup coil
resistanceTester se-
lector posi-
tion
248-372 Ω
at 20 °C (68
°F)Ω ×100
Tester (+) lead→Brown lead "1"
Tester (-) lead→Green lead "2"
Charging
coil 1 resis-
tanceTester se-
lector posi-
tion
720-1,080
Ω at 20 °C
(68 °F)Ω ×100

6-7
THROTTLE POSITION SENSOR SYSTEM
HANDLING NOTE
Do not loosen the screw (throttle
position sensor) "1" except when
changing the throttle position sen-
sor due to failure because it will
cause a drop in engine perfor-
mance.
CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
CHECKING THE THROTTLE
POSITION SENSOR COIL
1. Inspect:
• Throttle position sensor coil resis-
tance
Out of specification→Replace.
2. Loosen:
• Throttle stop screw "1"
Turn out the throttle stop screw until
the throttle shaft is in the full close po-
sition.
3. Inspect:
• Throttle position sensor coil vari-
able resistance
Check that the resistance in in-
creased as the throttle grip is
moved from the full close position
to the full open position.
Out of specification→Replace.
CHANGING AND ADJUSTING THE
THROTTLE POSITION SENSOR
1. Remove:
• Throttle position sensor coupler
•Carburetor
2. Remove:
• Screw (throttle position sensor)
"1"
• Throttle position sensor "2"
Loosen the screw (throttle position
sensor) using the T25 bit.
3. Replace:
• Throttle position sensor
4. Install:
• Throttle position sensor "1"
• Screw (throttle position sensor)
"2"
• Align the slot "a" in the throttle posi-
tion sensor with the projection "b"
on the carburetor.
• Temporarily tighten the screw
(throttle position sensor).
5. Install:
•Carburetor
• Throttle position sensor coupler
6. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section in
the CHAPTER 3.
7. Insert the thin electric conductors
"2" (lead) into the throttle position
sensor coupler "1", as shown, and
connect the tester to them.
• Do not insert the electric conduc-
tors more than required because
it may reduce the waterproof
function of the coupler.
• Make sure that a short-circuit
does not develop between the
terminals because it may cause
damage to electrical compo-
nents.
8. Start the engine.
9. Adjust:
• Throttle position sensor output
voltage
Adjustment steps:
a. Adjust the installation angle of the
throttle position sensor "1" to ob-
tain the specified output voltage.
Measure the output voltage accurate-
ly with a digital electronic voltmeter
that gives an easy reading of a small
voltage.
Tester (+) lead→Blue lead "1"
Tester (-) lead→Black lead "2"
Throttle po-
sition sen-
sor coil
resistanceTester se-
lector posi-
tion
4–6 kΩ at
20°C (68 °F) kΩ×1
Tester (+) lead→Yellow lead "1"
Tester (-) lead→Black lead "2"
Throttle position
sensor coil vari-
able resistanceTester
selec-
tor po-
sition
Full
closedFull
opened
kΩ×1 Zero –2
kΩat
20°C
(68 °F)4–6
kΩat
20 °C
(68 °F)
Tester (+) lead→Yellow lead "3"
Tester (-) lead→Black lead "4"

6-8
THROTTLE POSITION SENSOR SYSTEM
10. Put the aligning marks "a" on the
throttle position sensor and car-
buretor.
11. Stop the engine.
12. Remove the carburetor.
13. Tighten:
• Screw (throttle position sensor)
"1"
Tighten the screw (throttle position
sensor) using the T25 bit.
14. Install the carburetor.
CHECKING THE THROTTLE
POSITION SENSOR INPUT
VOLTAGE
1. Disconnect the throttle position
sensor coupler.
2. Start the engine.
3. Inspect:
• Throttle position sensor input volt-
age
Out of specification→Replace the
CDI unit.Throttle po-
sition sen-
sor output
voltageTester se-
lector posi-
tion
0.58–0.78 V DCV
Tester (+) lead→Blue lead "1"
Tester (-) lead→Black/Blue lead
"2"
Throttle po-
sition sen-
sor input
voltage Tester se-
lector posi-
tion
4–6 V DCV-20

7-1
ENGINE
TUNING
ENGINE
CARBURETOR SETTING
• The air/fuel mixture will vary de-
pending on atmospheric conditions.
Therefore, it is necessary to take
into consideration the air pressure,
ambient temperature, humidity,
etc., when adjusting the carburetor.
• Perform a test run to check for prop-
er engine performance (e.g., throt-
tle response) and spark plug(-s)
discoloration or fouling. Use these
readings to determine the best pos-
sible carburetor setting.
It is recommended to keep a record of
all carburetor settings and external
conditions (e.g., atmospheric condi-
tions, track/surface conditions, lap
times) to make future carburetor set-
ting easier.
• The carburetor is a part of the
fuel line. Therefore, be sure to in-
stall it in a wellventilated area,
away from flammable objects
and any sources of fire.
• Never look into the carburetor in-
take. Flames may shoot out from
the pipe if the engine backfires
while it is being started. Gasoline
may be discharged from the ac-
celerator pump nozzle when the
carburetor has been removed.
• The carburetor is extremely sen-
sitive to foreign matter (dirt,
sand, water, etc.). During instal-
lation, do not allow foreign mat-
ter to get into the carburetor.
• Always handle the carburetor
and its components carefully.
Even slight scratches, bends or
damage to carburetor parts may
prevent the carburetor from
functioning correctly. Carefully
perform all servicing with the ap-
propriate tools and without ap-
plying excessive force.
• When the engine is stopped or
when riding at no load, do not
open and close the throttle un-
necessarily. Otherwise, too
much fuel may be discharged,
starting may become difficult or
the engine may not run well.• After installing the carburetor,
check that the throttle operates
correctly and opens and closes
smoothly.
ATMOSPHERIC CONDITIONS AND
CARBURETOR SETTINGS
The air density (i.e., concentration of
oxygen in the air) determines the rich-
ness or leanness of the air/fuel mix-
ture.
• Higher temperature expands the air
with its resultant reduced density.
• Higher humidity reduces the
amount of oxygen in the air by so
much of the water vapor in the
same air.
• Lower atmospheric pressure (at a
high altitude) reduces the density of
the air.
EFFECT OF SETTING PARTS IN
RELATION TO THROTTLE VALVE
OPENING
A. Closed
B. Fully open
1. Pilot screw/pilot jet
2. Throttle valve cutaway
3. Jet needle
4. Main jetCONSTRUCTION OF
CARBURETOR AND SETTING
PARTS
The FLATCR carburetor has a prima-
ry main jet. This type of main jet is
perfect for racing machines since it
supplies an even flow of fuel, even at
full load. Use the main jet and the jet
needle to set the carburetor.
The FLATCR carburetor is manufac-
tured with a pilot screw. The pilot
screw adjustment ranges from fully
closed throttle to 1/4 open throttle.
1. Jet needle
2. Pilot air jet
3. Needle jet
4. Main jet
5. Pilot jet
6. Pilot screw
ADJUSTING THE MAIN JET
The richness of the air-fuel mixture at
full throttle can be set by changing the
main jet "1".
If the air-fuel mixture is too rich or too
lean, the engine power will drop, re-
sulting in poor acceleration.
Effects of changing the main jet
(reference)
A. Idle
B. Fully open
1. #162
2. #158
3. #160 Air
tem
p.Hu-
midi-
tyAir
pres-
sure
(alti-
tude)Mix-
tureSet-
ting
High HighLow
(high)Rich-
erLean-
er
Low LowHigh
(low)Lean-
erRich-
er
Standard main jet #160
7