2011 YAMAHA YZ450F sensor

7-2
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
WIRING DIAGRAM
1. Crankshaft position sensor
2. AC magneto
3. Rectifier/regulator
4. Condenser
5. Fuel pump
6. Engine stop switch
7. ECU
8. Ignition coil
9. Spark plug
10. Fuel injector
11. Intake air temperature sensor
12. Intake air pressure sensor
13. Throttle position sensor
14. Atmospheric pressure sensor
15. Coolant temperature sensor
16. Coupler for connecting optional part COLOR CODE
BBlack
Br Brown
Gy Gray
LBlue
Lg Light green
O Orange
PPink
RRed
WWhite
YYellow
B/L Black/Blue
B/R Black/Red
B/W Black/White
B/Y Black/Yellow
Br/W Brown/White
P/W Pink/White
R/B Red/Black
R/W Red/White
STOPON
Gy
Gy
B
B
/L
W1
W2
W2 O
R /B
R RR
R
R
R R
Lg
Lg Lg L
P
/W
P YB
/RB
B B
B
B BB
BB/W
B /W
B/W Br
/WGy
B /L
W1 W1
W2 W2 B
/Y
B /Y Br
B /R
R /W
OO
R /B
RR
R
L
P/W
P YL
L
LY
Br /WB /L
B /L
B/L
B
B/L
B/L
Br
W1
Br
/W
W2
R
R O
B/L
L
Y
B /L
Br
R
P
Gy
Gy
B /R
B
/R
R/WB /Y
B
/L
W1
W2
W1 R
R R
B
B
/Y
Lg Lg
O
R /B
R/B
Br /W
P /W P
/W
L L
Y
B /L B
/L
B/L
Br
B
B /W
B
/W
B
B
B L
B
/L
P

7-3
IGNITION SYSTEM
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure
and for checking the spark plug which will not spark.
*marked: Only when the ignition checker is used.
• Remove the following parts before inspection.
1. Seat
2. Fuel tank
• Use the following special tools in this inspection.
Spark gap testSpark→• *Clean or replace spark plug.
• Check the connection of the spark plug cap to the
spark plug.
No spark↓
Check entire ignition system for connection.
(couplers, leads and ignition coil)No good→
Repair or replace.
OK↓
Check engine stop switch. No good→Replace.
OK↓
Check ignition coil. (primary coil and secondary
coil)No good→
Replace.
OK↓
Check AC magneto. (crankshaft position sensor
and stator coil)No good→
Replace.
OK↓
Replace ECU.
Dynamic spark tester:
YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-03112-C/90890-03112

7-4
IGNITION SYSTEM
SPARK GAP TEST
1. Disconnect the spark plug cap
from spark plug.
2. Connect the dynamic spark tester
"1" (ignition checker "2") as
shown.
• Spark plug cap "3"
• Spark plug "4"
A. For USA and CDN
B. Except for USA and CDN
3. Kick the kickstarter crank.
4. Check the ignition spark gap.
5. Start engine, and increase spark
gap until misfire occurs. (for USA
and CDN only)
6. Inspect:
• Sealed portion of spark plug cap
"a"
• Spark plug terminal pin "b"
• Threaded portion of spark plug "c"
7. Inspect:
• Installed condition of spark plug
and spark plug cap
Push in the spark plug cap, mak-
ing sure that it is securely fitted
into the hole in the cylinder head
cover.CHECKING THE COUPLERS AND
LEADS CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→Repair or replace.
CHECKING THE ENGINE STOP
SWITCH
1. Inspect:
• Engine stop switch conduction
Not 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.
Disconnect the spark plug cap before
measuring the secondary coil resis-
tance.
CHECKING THE AC MAGNETO
1. Inspect:
• Crankshaft position sensor resis-
tance
Out of specification→Replace.
Minimum spark gap:
6.0 mm (0.24 in)
Tester (+) lead→Black lead "1"
Tester (-) lead→Black lead "2"
Result
Conductive (while the
engine stop switch is
pushed)
Tester (+) lead→Orange lead "1"
Tester (-) lead→Red lead "2"
Primary
coil resis-
tanceTester se-
lector posi-
tion
3.57–4.83
Ω at 20°C
(68°F) Ω × 1
BB
Tester (+) lead→Orange lead "1"
Tester (-) lead→Spark plug termi-
nal "2"
Secondary
coil resis-
tanceTester se-
lector posi-
tion
10.71–14.49
kΩ at 20°C
(68°F) kΩ × 1
Tester (+) lead→Gray lead "1"
Tester (-) lead→Black lead "2"
Crankshaft
position
sensor re-
sistanceTester se-
lector posi-
tion
248–372 Ω
at 20°C
(68°F)Ω × 100
GyB

7-5
IGNITION SYSTEM
2. Inspect:
• Stator coil resistance
Out of specification→Replace.
CHECKING THE ECU
1. Check:
• All electrical components.
2. Check:
• ECU installation status
Make sure that the ECU is in-
stalled correctly.
• The lean angle sensor is built into
the ECU.
• The lean angle sensor stops the en-
gine in case of a turnover.
• To ensure that the lean angle sen-
sor operates correctly, do not
change the installation position of
the sensor.
3. Check:
•ECU
If no fault is found, replace the
ECU. Tester (+) lead→White lead "1"
Tester (-) lead→White lead "2"
Stator coil
resistanceTester se-
lector posi-
tion
0.60–0.90
Ω at 20°C
(68°F)Ω × 10
W1 W2

7-6
THROTTLE POSITION SENSOR SYSTEM
THROTTLE POSITION SENSOR SYSTEM
INSPECTION STEPS
If the throttle position sensor will not operate, use the following inspection steps.
*marked: Refer to "IGNITION SYSTEM" section.
Use the following special tools in this inspection.
Check entire ignition system for connection. No good→Repair or replace.
OK↓
Check throttle position sensor. No good→Replace.
OK↓
*Check AC magneto. No good→Replace.
OK↓
Check ECU. (Throttle position sensor input volt-
age)No good→
Replace.
Model 88 Multimeter with tacometer:
YU-A1927
Digital circuit tester:
90890-03174
Test harness-speed sensor (3P):
YU-03208/90890-03208

7-7
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
1. Inspect:
• Throttle position sensor resis-
tance
Out of specification→Replace.2. Inspect:
• Throttle position sensor variable
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
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 projection "b" on the throt-
tle body with the slot "a" in the throt-
tle position sensor.
• Temporarily tighten the screw
(throttle position sensor).
5. Make sure that the throttle grip is
in the fully closed position.
6. Install:
• Throttle position sensor coupler
7. Connect the FI diagnostic tool.
(Refer to "CONNECTING THE FI
DIAGNOSTIC TOOL".)
8. Set the FI diagnostic tool to the di-
agnostic mode, and then select
diagnostic code No. D01. (Refer
to "SETTING THE DIAGNOSTIC
MODE".)
9. Adjust the position of the throttle
position sensor so that the angle
displayed on the LCD of the FI di-
agnostic tool is 12–21°.
10. After adjusting the throttle posi-
tion sensor angle, tighten the
throttle position sensor screw "1".
Tighten the screw (throttle position
sensor) using the T25 bit.
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
Y
B L
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)
Y
B L
Screw (throttle position
sensor)
3 Nm (0.3 m•kg, 2.2
ft•lb)

7-8
THROTTLE POSITION SENSOR SYSTEM
CHECKING THE THROTTLE
POSITION SENSOR INPUT
VOLTAGE
1. Disconnect the throttle position
sensor coupler.
2. Connect the test harness-speed
sensor (3P) "1" as shown.
3. Start the engine.
4. Inspect:
• Throttle position sensor input volt-
age
Out of specification → Replace
the ECU.Test harness-speed sen-
sor (3P)
YU-03208/90890-03208
Tester (+) lead→Blue lead (wire
harness color)
Tester (-) lead→Black/Blue lead
(wire harness color)
Throttle po-
sition sen-
sor input
voltage Tester se-
lector posi-
tion
4–6 V DCV-20

7-9
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
TROUBLESHOOTING METHOD
Engine starting problems, engine
idling speed problems, and medium
and high-speed performance prob-
lems
1. CHECK:
• Refer to "TROUBLESHOOTING"
section in the chapter 3.
2. Connect the FI diagnostic tool.
(Refer to "CONNECTING THE FI
DIAGNOSTIC TOOL".)
3. Check the fault code number.
(Refer to "TROUBLESHOOTING
DETAILS".)
• Check the fault code number that is
displayed on the LCD of the FI diag-
nostic tool.
• Identify the system with the mal-
function.(Refer to "TROUBLE-
SHOOTING DETAILS".)
4. Checking and repair the probable
case of malfunction.
• Fault code No. YES.
Check and repair.
Refer to "TROUBLESHOOTING
DETAILS".
Refer to "SENSOR OPERATION
TABLE".
• Fault code No. NO.
Check each sensor and actuator
in the diagnostic mode.
Refer to "SETTING THE DIAG-
NOSTIC MODE".
Refer to "SENSOR OPERATION
TABLE".
If the sensors or actuators are
damaged, check and, if neces-
sary, repair or replace all faulty
parts.
If the sensors or actuators are not
damaged, check and, if neces-
sary, repair or replace the engine
inner parts.5. Perform ECU reinstatement ac-
tion.
Refer to "Reinstatement method"
of table in "TROUBLESHOOTING
DETAILS".
6. Set the switch on the FI diagnostic
tool sub-wire harness from "OFF"
to "ON", and then check whether
a fault code number is displayed
again.
If other fault code displayed, repeat
steps (2) to (5) until all fault code
number is not displayed.
7. Set the switch on the FI diagnostic
tool sub-wire harness to "OFF",
and then disconnect the FI diag-
nostic tool, FI diagnostic tool sub-
wire harness, and battery. Place
the accessory coupler in its origi-
nal position.
The malfunction history is stored
even if the switch on the FI diagnostic
tool sub-wire harness is set to "OFF".
Erase the malfunction history in the
diagnostic mode. (Refer to "DIAG-
NOSTIC CODE TABLE (Diagnostic
code No. D62)".)
CONNECTING THE FI
DIAGNOSTIC TOOL
1. Connect the following items to the
accessory coupler as shown.
• FI diagnostic tool "1"
• FI diagnostic tool sub-wire har-
ness "2"
• Battery "3"
• Because this vehicle is not
equipped with a battery, a 12 V
battery is required to use the FI di-
agnostic tool.
• Make sure that the switch on the
FI diagnostic tool sub-wire har-
ness is set to "OFF".
• The "POWER" LED (green)
comes on.
CHECKING THE FAULT CODES
1. Set the switch on the FI diagnostic
tool subwire harness to "ON".
When the switch on the FI diagnostic
tool sub-wire harness is set to "ON",
make sure that "Waiting for connec-
tion" is displayed on the LCD of the FI
diagnostic tool.
2. Check:
• Fault code number
• If a malfunction is detected in the
system, the fault code appears on
the LCD of the FI diagnostic tool
and the "WARNING" LED (orange)
comes on.
• To start the engine, set the switch
on the FI diagnostic tool sub-wire
harness to "OFF".
• When the engine is running, fault
code numbers will not be displayed
on the LCD of the FI diagnostic tool
even if a malfunction is detected in
the system. The "WARNING" LED
(orange) comes on.
3. Set the switch on the FI diagnostic
tool subwire harness to "OFF". FI diagnostic tool
YU-03182/90890-03182
FI diagnostic tool sub-
wire harness
YU-03212/90890-03212
2100 60
60