2015 YAMAHA YZ450F Owners Manual

RADIATOR
6-2
4 Radiator hose 2 1
5 Radiator hose 3 1
6 Radiator hose 4 1
7 Radiator pipe 2 1
8 Radiator breather hose 1
9 Left radiator 1
10 Radiator hose 1 1
11 Radiator pipe 1 1
12 Coolant temperature sensor 1
For installation, reverse the removal proce-
dure.
Removing the radiator
Order Part name Q’ty Remarks
11
12
New
New
New
LS
LS

RADIATOR
6-3
EAS1SL5297HANDLING NOTEEWA1DX1007
WARNING
If coolant seems hot, do not remove the ra-
diator cap.
EAS1SL5298CHECKING THE RADIATOR
1. Check:
• Radiator fins “1”
Obstructions  Clean.
Apply compressed air to the rear of the radi-
ator.
Damage  Repair or replace.
TIP
Correct any flattened fins with a thin, flat-head
screwdriver.
2. Check:
• Radiator hoses
• Radiator pipes
Crack/damage  Replace.

WATER PUMP
6-4
EAS1SL5299
WATER PUMP
Removing the water pump
Order Part name Q’ty Remarks
CoolantDrain.
Refer to “CHANGING THE COOLANT” on
page 3-8.
Engine oilDrain.
Refer to “CHANGING THE ENGINE OIL” on
page 3-15.
Right crankcase cover Refer to “CLUTCH” on page 5-37.
1 Water pump housing 1
2 Dowel pin 2
3Gasket 1
4Collar 1
5Pin 1
6 Impeller shaft assembly 1
7 Oil seal 1
8 Bearing 1
9 Oil seal 1
For installation, reverse the removal proce-
dure.
LS
LS
7
6
2
2
3
1
854
New
New
New
E
9
New
E
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.
10 Nm (1.0 m kgf, 7.2 ft Ibf)T.R.

WATER PUMP
6-5
EAS1SL5300REMOVING THE OIL SEAL
TIP
• Remove the oil seal when the coolant level
changes frequently more than usual, coolant
has discolored, or engine oil has become
milky.
• Do not use the removed oil seal.
1. Remove:
• Oil seals “1”
EAS1SL5301CHECKING THE WATER PUMP
1. Check:
• Water pump housing cover
• Impeller shaft
Cracks/damage/wear  Replace.
EAS1SL5302CHECKING THE BEARING
1. Check:
• Bearing
Rotate the inner race with your finger.
Rough spot/seizure  Replace.
EAS1SL5303INSTALLING THE OIL SEAL
1. Install:
• Oil seals “1”
TIP
• Apply the lithium soap base grease on the oil
seal lip.
• Install the oil seal with its manufacture’s
marks or numbers facing the right crankcase
cover “2”.2. Install:
• Bearing “1”
TIP
Install the bearing by pressing its outer race
parallel.
EAS1SL5304ASSEMBLING THE WATER PUMP
1. Install:
• Impeller shaft assembly “1”
•Pin “2”
• Collar “3”
• Circlip “4”
TIP
• Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its posi-
tion.
• When installing the impeller shaft, apply the
engine oil to the oil seal lip, the bearing, and
the impeller shaft.
1 1
New
1 1New
New
LS
LS
New
4
1
23New
E

WATER PUMP
6-6
2. Install:
• Dowel pin “1”
• Gasket “2”
3. Install:
• Water pump housing “1”
• Water pump housing bolt “2”
• Washer “3”
• Coolant drain bolt “4”Water pump housing bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
New
21
1New
T R..
New
T R..
2
2
43 1
New

WATER PUMP
6-7

7
FUEL SYSTEM
FUEL TANK...................................................................................................... 7-1
REMOVING THE FUEL TANK ................................................................... 7-2
REMOVING THE FUEL PUMP .................................................................. 7-2
CHECKING THE FUEL PUMP BODY........................................................ 7-2
INSTALLING THE FUEL PUMP ................................................................. 7-2
INSTALLING THE FUEL TANK.................................................................. 7-3
CHECKING THE FUEL PRESSURE ......................................................... 7-3
CHECKING THE DAMPER ........................................................................ 7-4
CHECKING AND REPLACING THE PROTECTOR .................................. 7-4
THROTTLE BODY............................................................................................ 7-5
CHECKING THE INJECTOR ..................................................................... 7-8
CHECKING THE THROTTLE BODY ......................................................... 7-8
CHECKING THE THROTTLE BODY JOINT .............................................. 7-8
ADJUSTING THE THROTTLE POSITION SENSOR................................. 7-9

FUEL TANK
7-1
EAS1SL5305
TIP
This section is intended for those who have basic knowledge and skill concerning the servicing of
Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowl-
edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas-
sembly, or reassembly only by reference to this manual. It may lead to servicing trouble and
mechanical damage.
EAS1SL5306
FUEL TANK
Removing the fuel tank
Order Part name Q’ty Remarks
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right)
Air scoop (left/right)
1 Fuel pump coupler 1 Disconnect.
2 Fuel hose 1 Disconnect.
3Fuel tank 1
4 Fuel pump bracket 1
5 Fuel pump 1
6 Fuel pump gasket 1
For installation, reverse the removal proce-
dure.
4(6) (2)
(2) (2)(2)2
5
6
3
1
New
4.0 Nm (0.40 mkgf, 2.9 ftIbf)T.R
.
7 Nm (0.7 mkgf, 5.1 ftIbf)T.R.
7 Nm (0.7 mkgf, 5.1 ftIbf)T.R.
7 Nm (0.7 mkgf, 5.1 ftIbf)T.R.
9 Nm (0.9 mkgf, 6.5 ftIbf)T.R.
4.0 Nm (0.40 mkgf, 2.9 ftIbf)T.R
.