2015 YAMAHA YZ450F Owners Manual

FUEL TANK
7-2
EAS1SL5307REMOVING THE FUEL TANK
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel hose coupler
EWA23P1001
WARNING
Cover the fuel hose connection with a cloth
when disconnecting it. This is because re-
sidual pressure in the fuel hose could cause
fuel to spurt out when the hose is removed.
ECA23P1090
NOTICE
Make sure that the fuel hose is disconnect-
ed by hand. Do not forcefully disconnect the
hose with tools.
TIP
• To disconnect the fuel hose from the fuel tank,
remove the fuel hose connector holder “a”,
and then slide the fuel hose connector cover.
• To remove the fuel hose from the fuel rail,
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown, press the two buttons “2” on the sides
of the connector, and then remove the hose.
• Before removing the hose, place a few cloths
in the area under where it will be removed.
• To prevent sand, dust, and other foreign ma-
terials from entering the fuel pump, install the
included fuel hose joint cover 1 “3” and the
fuel hose joint cover 2 “4” onto the disconnect-
ed fuel hose and the fuel pump.3. Remove:
• Side cover (left/right)
• Seat
• Air scoop (left/right)
• Fuel tank
TIP
Do not set the fuel tank down on the installation
surface of the fuel pump. Be sure to lean the
fuel tank against a wall or the like.
EAS1SL5308REMOVING THE FUEL PUMP
1. Remove:
• Fuel pump
ECA14720
NOTICE
Do not drop the fuel pump or give it a strong
shock.
EAS1SL5309CHECKING THE FUEL PUMP BODY
1. Check:
• Fuel pump body
Obstructions  Clean.
Cracks/damage  Replace the fuel pump
assembly.
EAS1SL5310INSTALLING THE FUEL PUMP
1. Install:
• Fuel pump gasket
• Fuel pump
• Fuel pump bracket
a
1
2
Fuel pump bolts
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
3 4
New
T R..

FUEL TANK
7-3
TIP
• Take care not to damage the installation sur-
faces of the fuel tank.
• Always use a new fuel pump gasket.
• Install the lip on the fuel pump gasket upward.
• Install the fuel pump as shown in the figure.
• Align the projection “a” on the fuel pump with
the slot “b” in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
EAS1SL5311INSTALLING THE FUEL TANK
1. Install:
• Fuel tank
2. Connect:
• Fuel hose
ECA33DD069
NOTICE
• Connect the fuel hose securely, and check
that the orientation of the installed fuel
hose holder is correct.
• Take care not to kink or pinch the fuel
hose.
TIP
• Insert the fuel hose into the fuel pipe securely
until you hear a “click”.
• Slide the fuel hose connector cover “1” at the
hose end in the direction of the arrow.
• Install the fuel hose connector holder “a”.
• Check that the fuel hose and the fuel pump
lead are routed through the guide on the cov-
er.3. Connect:
• Fuel pump coupler
4. Install:
• Air scoop (left/right)
• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 4-
1.
EAS1SL5312CHECKING THE FUEL PRESSURE
1. Check:
• Fuel pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the side cover (left/right), the seat
and the air scoop (left/right).
Refer to “GENERAL CHASSIS” on page 4-
1.
b. Remove the fuel tank bolt and lift the fuel
tank.
c. Disconnect the fuel hose from the fuel
pump.
Refer to “REMOVING THE FUEL TANK” on
page 7-2.
EWA1DX1008
WARNING
Cover the fuel hose connection with a cloth
when disconnecting it. This is because re-
sidual pressure in the fuel hose could cause
fuel to spurt out when the hose is removed.
ECA1DX1025
NOTICE
Make sure that the fuel hose is disconnect-
ed by hand. Do not forcibly disconnect the
hose with tools.
a
b
4 1
2
6
53
1
a

FUEL TANK
7-4
d. Connect the pressure gauge “1” and the fuel
pressure adapter “2” to the fuel hose.
e. Start the engine.
f. Measure the fuel pressure.
Out of specification  Replace the fuel
pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS1SL5313CHECKING THE DAMPER
1. Check:
• Damper 1 “1”
• Damper 2 “2”
• Damper 3 “3”
Wear/damage  Replace.
TIP
• Affix dampers 1 and 3 with the arrow on each
damper pointing outward.
• Affix the damper 2 with its projection “a” facing
the rear of the vehicle.
EAS1SL5314
CHECKING AND REPLACING THE PRO-
TECTOR
1. Check:
• Protector “1”
Wear/damage  Replace.
TIP
Affix the protector as shown. Pressure gauge
90890-03153
YU-03153
Fuel pressure adapter
90890-03186
YM-03186
Fuel pressure
324.0 kPa (3.24 kgf/cm
2, 47.0
psi)
1
2
84 mm
(3.31 in)115 mm
(4.53 in)
84 mm
(3.31 in)115 mm
(4.53 in)
3 1
13a
2
A. Left
B. Right
1
1
0 mm
(0 in)
A
B
1
15 mm
(0.59 in)
1

THROTTLE BODY
7-5
EAS1SL5315
THROTTLE BODY
Removing the throttle body
Order Part name Q’ty Remarks
Seat Refer 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 tank Refer to “FUEL TANK” on page 7-1.
ECU Refer to “ENGINE REMOVAL” on page 5-1.
Ignition coil Refer to “ENGINE REMOVAL” on page 5-1.
1 Intake air temperature sensor coupler 1 Disconnect.
2 Air filter case 1
3 Fuel injector coupler 1 Disconnect.
4 Intake air pressure sensor coupler 1 Disconnect.
5 Throttle position sensor coupler 1 Disconnect.
6 Throttle cable cover 1
7 Throttle cable 2
8 Fuel hose 1
9 Exhaust pipe bracket 1
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.

THROTTLE BODY
7-6
10Throttle body
1
11 Throttle body joint 1
For installation, reverse the removal proce-
dure.
Removing the throttle body
Order Part name Q’ty Remarks
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.

THROTTLE BODY
7-7
Removing the injector
Order Part name Q’ty Remarks
1 Fuel inlet pipe 1
2Injector 1
3 Gaskets 1
4 Throttle position sensor 1
5 Intake air pressure sensor 1
For installation, reverse the removal proce-
dure.
1
2 (2)
(2)5
43
T.R.3.4 Nm (0.34 mlbf) kgf, 2.5 ft
T.R.5 Nm (0.5 mlbf) kgf, 3.6 ft
T.R.3.4 Nm (0.34 mlbf) kgf, 2.5 ft

THROTTLE BODY
7-8
EAS1SL5316CHECKING THE INJECTOR
1. Check:
• Injector
Obstruction  Replace, and check the fuel
pump and the fuel injection system.
Refer to “FUEL INJECTION SYSTEM” on
page 8-10.
Deposits  Replace.
Damage  Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJEC-
TOR” on page 8-47.
EAS1SL5317CHECKING THE THROTTLE BODY
1. Check:
• Throttle body
Cracks/damage  Replace.
2. Check:
• Fuel passages
Obstructions  Clean.
ECA1DX1027
NOTICE
• Before removing the throttle body, clean
the area around the throttle body to pre-
vent dirt and other foreign material from
falling into the engine.
• If the throttle body is subject to strong
shocks or dropped during cleaning, re-
place it.
• Do not use any caustic carburetor clean-
ing solution.
• Do not directly push the throttle valves to
open them.
• Do not loosen the throttle valve stopper
screw “1”, throttle valve pulley nut “2”, or
throttle valve screw “3”. A loss of perfor-
mance may occur.
• Do not use compressed air to clean the
throttle body. Foreign materials may ad-
here to the intake air pressure sensor pas-
sage “a” and fuel injector “b” in the
throttle body.3. Check:
• Starter knob/idle screw passage “c”
Obstruction  Blow out with compressed
air.
EAS1SL5318CHECKING THE THROTTLE BODY JOINT
1. Check:
• Throttle body joint “1”
Crack/damage  Replace.
1 2
3
ba
c
1

THROTTLE BODY
7-9
EAS1SL5319ADJUSTING THE THROTTLE POSITION
SENSOR
EWA32D1011
WARNING
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
• Throttle position sensor
Refer to “CHECKING THE THROTTLE PO-
SITION SENSOR” on page 8-44.
2. Adjust:
• Throttle position sensor angle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Yamaha diagnostic tool.
Refer to “YAMAHA DIAGNOSTIC TOOL” on
page 8-12.
b. Temporary tighten the throttle position sen-
sor.
c. Check that the throttle grip is fully closed.
d. Connect the throttle position sensor to the
wire harness.
e. Set the Yamaha diagnostic tool to “diagnos-
tic mode”.
f. Choose the diagnostic code No. “01”.
g. Adjust the throttle position sensor mounted
angle until “11？14” appears on the Yama-
ha diagnostic tool.
h. After adjusting the throttle position sensor
mounted angle, tighten the throttle position
sensor screws “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Yamaha diagnostic tool
90890-03231
Yamaha diagnostic tool (US)
90890-03234
Throttle position sensor screw
3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
T R..
1