2014 YAMAHA YZ450F oil pressure
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CLUTCH......................................................................................................... 5-37
REMOVING THE CLUTCH ...................................................................... 5-40
CHECKING THE FRICTION PLATES...................................................... 5-40
CHECKING THE CLUTCH PLATES ........................................................ 5-40
CHECKING THE CLUTCH SPRINGS...................................................... 5-40
CHECKING THE CLUTCH HOUSING ..................................................... 5-41
CHECKING THE CLUTCH BOSS ............................................................ 5-41
CHECKING THE PRESSURE PLATE ..................................................... 5-41
CHECKING THE PUSH LEVER SHAFT .................................................. 5-41
CHECKING THE CLUTCH PUSH RODS ................................................ 5-41
CHECKING THE PRIMARY DRIVE GEAR .............................................. 5-41
CHECKING THE PRIMARY DRIVEN GEAR ........................................... 5-42
INSTALLING THE OIL SEAL................................................................... 5-42
INSTALLING THE RIGHT CRANKCASE COVER ................................... 5-42
INSTALLING THE CLUTCH ..................................................................... 5-42
INSTALLING THE KICKSTARTER LEVER ............................................. 5-45
KICKSTATER................................................................................................. 5-46
REMOVING THE KICK SHAFT ASSEMBLY ........................................... 5-47
CHECKING THE KICK SHAFT AND RATCHET WHEEL ........................ 5-47
CHECKING THE KICK GEAR, KICK IDLE GEAR,
AND RATCHET WHEEL ......................................................................... 5-47
INSTALLING THE KICK SHAFT ASSEMBLY .......................................... 5-47
INSTALLING THE KICK IDLE GEAR ....................................................... 5-48
SHIFT SHAFT................................................................................................. 5-49
REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 5-51
REMOVING THE SEGMENT ................................................................... 5-51
CHECKING THE SHIFT SHAFT .............................................................. 5-51
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ......... 5-51
CHECKING THE STOPPER LEVER ....................................................... 5-51
INSTALLING THE STOPPER LEVER ..................................................... 5-52
INSTALLING THE SEGMENT.................................................................. 5-52
INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY ....... 5-52
INSTALLING THE SHIFT SHAFT ............................................................ 5-53
INSTALLING THE SHIFT PEDAL ............................................................ 5-53
OIL PUMP AND BALANCER GEAR............................................................. 5-54
REMOVING THE BALANCER ................................................................. 5-56
CHECKING THE PRIMARY DRIVE GEAR, BALANCER SHAFT
DRIVE GEAR, AND BALANCER WEIGHT GEAR ................................. 5-56
CHECKING THE BALANCER .................................................................. 5-56
CHECKING THE OIL PUMP .................................................................... 5-56
ASSEMBLING THE OIL PUMP ................................................................ 5-57
INSTALLING THE OIL PUMP AND BALANCER GEAR .......................... 5-57
Page 232 of 360
CLUTCH
5-37
EAS1SL1232
CLUTCH
Removing the clutch
OrderPart nameQ’tyRemarks
Engine oilDrain.Refer to “CHANGING THE ENGINE OIL” on page 3-15.
Brake pedalRefer to “ENGINE REMOVAL” on page 5-1.
1Clutch cable1Disconnect.
2Clutch cover1
3O-ring1
4Clutch spring6
5Pressure plate1
6Push rod 11
7Circlip1
8Washers1
9Bearing1
10Ball1
11Push rod 21
12Friction plate 15
13Clutch plate7
LS
LS
New
New
New
2
3 45
789
61011
13
12
12
18
1
14
13
13
17
16
15
T.R.
T.R.
T.R.
T.R.
LT
Page 239 of 360
CLUTCH
5-44
6. Install:
• Push rod 2 “1”
•Ball “2”
• Push rod 1 “3”
TIP
Apply the engine oil on the push rod 1, 2 and
ball.
7. Install:
• Pressure plate “1”
8. Install:
• Clutch spring
• Clutch spring bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
9. Install:
• O-ring “1”
TIP
Apply the lithium-soap-based grease to the O-
ring.
10.Install:
• Clutch cover “1”
• Clutch cover bolt
TIP
Tighten the bolts in stages and in a crisscross
pattern.
EAS1SL1247
Clutch spring bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)T R..
Clutch cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
New
T R..
1
Page 284 of 360
THROTTLE BODY
7-5
EAS1SL1314
THROTTLE BODY
Removing the throttle body
OrderPart nameQ’tyRemarks
SeatRefer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right)Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left/right)Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tankRefer to “FUEL TANK” on page 7-1.
ECURefer to “ENGINE REMOVAL” on page 5-1.
Ignition coilRefer to “ENGINE REMOVAL” on page 5-1.
1Intake air temperature sensor coupler1Disconnect.
2Air filter case1
3Fuel injector coupler1Disconnect.
4Intake air pressure sensor coupler1Disconnect.
5Throttle position sensor coupler1Disconnect.
6Throttle cable cover1
7Throttle cable2
8Fuel hose1
9Exhaust pipe bracket1
2
1
6
10
11
9
8
3
7
5
4
3.5 Nm (0.35 mkgf, 2.5 ftIbf)T.R.
3.5 Nm (0.35 mkgf, 2.5 ftIbf)T.R.
7 Nm (0.7 mkgf, 5.1 ftIbf)T.R.
3.0 Nm (0.30 mkgf, 2.2 ftIbf)T.R.
10 Nm (1.0 mkgf, 7.2 ftIbf)T.R.
Page 289 of 360
8
ELECTRICAL SYSTEM
IGNITION SYSTEM.......................................................................................... 8-2
CIRCUIT DIAGRAM ................................................................................... 8-2
TROUBLESHOOTING ............................................................................... 8-4
CHARGING SYSTEM....................................................................................... 8-6
CIRCUIT DIAGRAM ................................................................................... 8-6
TROUBLE SHOOTING .............................................................................. 8-8
FUEL INJECTION SYSTEM........................................................................... 8-10
CIRCUIT DIAGRAM ................................................................................. 8-10
YAMAHA DIAGNOSTIC TOOL ................................................................ 8-12
TROUBLESHOOTING DETAILS ............................................................. 8-13
FUEL PUMP SYSTEM.................................................................................... 8-32
CIRCUIT DIAGRAM ................................................................................. 8-32
TROUBLESHOOTING ............................................................................. 8-34
ELECTRICAL COMPONENTS....................................................................... 8-36
CHECKING THE SWITCHES .................................................................. 8-38
CHECKING THE IGNITION SPARK GAP................................................ 8-41
CHECKING THE SPARK PLUG CAP ...................................................... 8-41
CHECKING THE IGNITION COIL ............................................................ 8-41
CHECKING THE CRANKSHAFT POSITION SENSOR........................... 8-42
CHECKING THE ECU .............................................................................. 8-43
CHECKING THE STATOR COIL ............................................................. 8-43
CHECKING THE RECTIFIER/REGULATOR ........................................... 8-43
CHECKING THE COOLANT TEMPERATURE SENSOR........................ 8-44
CHECKING THE THROTTLE POSITION SENSOR ................................ 8-44
CHECKING THE THROTTLE POSITION SENSOR
INPUT VOLTAGE .................................................................................... 8-43
CHECKING THE INTAKE AIR PRESSURE SENSOR ............................ 8-46
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................... 8-46
CHECKING THE NEUTRAL SWITCH ..................................................... 8-46
CHECKING THE FUEL INJECTOR ......................................................... 8-47
Page 327 of 360
ELECTRICAL COMPONENTS
8-37
EAS1SL1334
1. Rectifier/regulator
2. Intake air pressure sensor
3. Throttle position sensor
4. Injector
5. Intake air temperature sensor
6. ECU
7. Ignition coil
8. Condenser
9. Neutral switch
10.Coolant temperature sensor
Page 341 of 360
TROUBLE SHOOTING
9-2
3. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
EAS1SL1353POOR MEDIUM-AND-HIGH-SPEED PER-
FORMANCE
Refer to “STARTING FAILURES” on page 9-1.
Engine
1. Air filter
• Clogged air filter element
Fuel system
1. Fuel pump
• Faulty fuel pump
2. Throttle body
• Defective throttle body
3. ECU
• Faulty ECU
EAS1SL1354FAULTY GEAR SHIFTING
Shifting is difficult
Refer to “CLUTCH” on page 5-37.
EAS1SL1355SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Bent shift shaft
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EAS1SL1356JUMPS OUT OF GEAR
Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Incorrect axial play
• Worn shift drum groove
Transmission
• Worn gear dog
EAS1SL1357FAULTY CLUTCH
Clutch slips
1. Clutch
• Improperly assembled clutch
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
Clutch drags
1. Clutch
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Damaged clutch boss
• Burnt primary driven gear bushing
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS1SL1358OVERHEATING
Engine
1. Cylinder head and piston
• Heavy carbon buildup
• Clogged coolant passages
2. Engine oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
Cooling system
1. Coolant
• Low coolant level
2. Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
3. Water pump
• Damaged or faulty water pump
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
Page 342 of 360
TROUBLE SHOOTING
9-3
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
2. Air filter
• Clogged air filter element
Chassis
1. Brake(s)
• Dragging brake
Electrical system
1. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
2. Ignition system
• Faulty ECU
• Faulty coolant temperature sensor
EAS1SL1359OVERCOOLING
Cooling system
• Faulty coolant temperature sensor
EAS1SL1360POOR BRAKING PERFORMANCE
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Defective master cylinder kit
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS1SL1361FAULTY FRONT FORK LEGS
Leaking oil
• Bent, damaged, or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt copper
washer
• Cracked or damaged cap bolt O-ring
Malfunction
• Bent or damaged inner tube
• Bent or damaged outer tube
• Broken fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS1SL1362UNSTABLE HANDLING
1. Handlebar
• Bent or improperly installed handlebar
2. Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
3. Front fork leg (s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
4. Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
5. Rear shock absorber assembly (-ies)
• Faulty rear shock absorber spring
• Leaking oil or gas
6. Tire (s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
7. Wheel (s)
• Incorrect wheel balance
• Broken or loose spoke
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
8. Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race