2015 YAMAHA YZ450F Owners Manual

CABLE ROUTING DIAGRAM
2-38
1. Throttle cable
2. Clutch cable
3. Engine stop switch lead
4. Cable guide
5. Head pipe
6. Front brake hose
7. Brake hose guide
8. Number plate
A. Number plate band
B. Pass the clutch cable to the rear of the number
plate band.
C. Clamp the engine stop switch lead to the handle-
bar by the plastic band. Do not cut the end of the
plastic band.
D. Pass the engine stop switch lead between the
head pipe and the cable guide.
E. Pass the front brake hose to the front of the num-
ber plate.
F. 40°±10°
G. Vertical direction
H. Pass the engine stop switch lead under the han-
dlebar.
I. Pass the clutch cable to the guide in the number
plate.

CABLE ROUTING DIAGRAM
2-39

CABLE ROUTING DIAGRAM
2-40
1. Main harness
2. Radiator
3. Throttle position sensor lead
4. Joint coupler
5. Intake air temperature sensor lead
6. Intake air pressure sensor lead
7. Frame
8. Fuel hose
9. High tension cord
10. Spark plug cap
11. Cylinder head cover
12. Sub-wire harness
13. Injector coupler
14. Injector lead
15. Throttle body
16. Air filter case
17. ECU
18. Sub-wire harness coupler
A. Fix the main harness by the plastic clamp, and in-
sert the projection of the plastic clamp into the
hole in the sheet metal of the radiator.
B. Insert the projection of the main harness into the
hole in the frame.
C. To the sub-wire harness
D. Pass the high tension cord above the fuel hose.
E. ±10°
F. Install the spark plug cap with this facing the right
of the vehicle.
G. Push the spark plug cap home, where there shall
be no gap between it and the cylinder head cover.
H. Pass the injector lead to the top of the vehicle be-
yond the fuel hose.
I. Insert the coupler of the sub-wire harness into the
rib of the air filter case.
J. Pass the sub-wire harness between the ECU and
the air filter case.

CABLE ROUTING DIAGRAM
2-41

CABLE ROUTING DIAGRAM
2-42
1. Brake master cylinder
2. Brake hose holder
3. Brake hoses
A. While installing the brake hose, direct a bend in
its pipe portion as shown, and bring it into contact
with the projection on the brake caliper.
B. Pass the brake hose into the brake hose holders.
C. If the brake hose interferes with the rear shock
absorber, correct its twist.
D. While installing the brake hose, direct a bend in
its pipe portion as shown, and bring it into contact
with the projection on the brake master cylinder.

CABLE ROUTING DIAGRAM
2-43

3
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS.......................................................................... 3-1
MAINTENANCE INTERVALS .................................................................... 3-1
PRE-OPERATION INSPECTION AND MAINTENANCE................................. 3-7
GENERAL INSPECTION AND MAINTENANCE........................................ 3-7
ENGINE............................................................................................................ 3-8
CHECKING THE COOLANT LEVEL .......................................................... 3-8
CHECKING THE COOLING SYSTEM ....................................................... 3-8
CHANGING THE COOLANT...................................................................... 3-8
CHECKING THE RADIATOR CAP ............................................................ 3-9
CHECKING THE RADIATOR CAP OPENING PRESSURE ...................... 3-9
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-10
ADJUSTING THE CLUTCH LEVER POSITION ...................................... 3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-10
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-11
LUBRICATING THE THROTTLE CABLE ................................................ 3-12
CLEANING THE AIR FILTER ELEMENT................................................. 3-12
CHECKING THE THROTTLE BODY JOINT ............................................ 3-13
CHECKING THE BREATHER HOSES .................................................... 3-13
CHECKING THE EXHAUST SYSTEM..................................................... 3-13
CHECKING THE FUEL LINE ................................................................... 3-14
CHECKING THE ENGINE OIL LEVEL..................................................... 3-14
CHANGING THE ENGINE OIL ................................................................ 3-15
ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-16
ADJUSTING THE VALVE CLEARANCE ................................................. 3-17
CHASSIS........................................................................................................ 3-21
BLEEDING THE BRAKE SYSTEM .......................................................... 3-21
CHECKING THE BRAKE HOSE .............................................................. 3-22
ADJUSTING THE FRONT BRAKE .......................................................... 3-22
ADJUSTING THE REAR BRAKE ............................................................. 3-23
CHECKING THE FRONT BRAKE PADS ................................................. 3-23
CHECKING THE REAR BRAKE PADS ................................................... 3-25
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-26
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-26
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-27
CHECKING THE FRONT FORK LEGS ................................................... 3-28
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-28
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................ 3-28
AIR BLEEDING FROM FRONT FORK .................................................... 3-28
ADJUSTING THE FRONT FORK LEGS .................................................. 3-29
CHECKING THE SWINGARM OPERATION ........................................... 3-30
CHECKING THE REAR SUSPENSION ................................................... 3-30
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-30
CHECKING THE TIRES ........................................................................... 3-32
CHECKING AND TIGHTENING THE SPOKES ....................................... 3-32
CHECKING THE WHEELS ...................................................................... 3-33

CHECKING THE WHEEL BEARINGS ..................................................... 3-33
CHECKING AND ADJUSTING THE STEERING HEAD .......................... 3-33
LUBRICATING THE LEVERS .................................................................. 3-34
LUBRICATING THE PEDAL .................................................................... 3-34
ELECTRICAL SYSTEM.................................................................................. 3-35
CHECKING THE SPARK PLUG .............................................................. 3-35
CHECKING THE IGNITION TIMING ........................................................ 3-35