YAMAHA YFZ450R YFZ450 ATV Service Repair Manual 2009-2013

SERVICE MANUAL

EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal- ers and will appear in future editions of this manual where applicable. TIP • This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. • Designs and specifications are subject to change without notice. EAS20081 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations. This is the safety alert symbol. It is used to alert you to potential per- sonal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. A TIP provides key information to make procedures easier or clearer. WARNING NOTICE TIP

HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title is shown at the top of each page “1”. • Sub-section titles appear in smaller print than the section title “2”. • To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section “3”. • Numbers are given in the order of the jobs in the exploded diagram. A number indicates a disassembly step “4”. • Symbols indicate parts to be lubricated or replaced “5”. Refer to “SYMBOLS”. • A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc “6”. • Jobs requiring more information (such as special tools and technical data) are described sequen- tially “7”.

EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. TIP The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium-soap-based grease Wear limit, clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent (LOC- TITE®). Engine oil Replace the part with a new one.

1 2 3 4 5 6 7 8 9 EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING

1 GENERAL INFORMATION IDENTIFICATION .......................................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ................................................... 1-1 MODEL LABEL ....................................................................................... 1-1 FEATURES ................................................................................................... 1-2 OUTLINE OF THE FI SYSTEM .............................................................. 1-2 FI SYSTEM ............................................................................................. 1-3 IMPORTANT INFORMATION ....................................................................... 1-4 PREPARATION FOR REMOVAL AND DISASSEMBLY .......................... 1-4 REPLACEMENT PARTS......................................................................... 1-4 GASKETS, OIL SEALS AND O-RINGS.................................................. 1-4 LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-4 BEARINGS AND OIL SEALS ................................................................. 1-5 CIRCLIPS ............................................................................................... 1-5 CHECKING THE CONNECTIONS ............................................................... 1-6 SPECIAL TOOLS.......................................................................................... 1-7

IDENTIFICATION 1-1 EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the left side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the air filter case cover. This information will be needed to order spare parts.

FEATURES 1-2 EAS20170 FEATURES EAS30340 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man- ner. To accommodate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. 1. Engine trouble warning light 2. Fuel level warning light 3. Fuel pump 4. Ignition coil 5. Intake air pressure sensor 6. Injector 7. Intake air temperature sensor 8. ECU (engine control unit) 9. Battery 10.Lean angle sensor 11.ISC (idle speed control) valve 12.Throttle position sensor 13.Speed sensor 14.Crankshaft position sensor 15.Coolant temperature sensor

FEATURES 1-3 EAS18P1001 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm², 47.0 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied. The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake temperature sensor and coolant temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions. 1. Fuel pump 2. Fuel sender 3. Main relay 4. Injector 5. Ignition coil 6. Lean angle sensor 7. Battery 8. Speed sensor 9. Neutral switch 10.Clutch switch 11.Start switch 12.Coolant temperature sensor 13.ECU (engine control unit) 14.Radiator fan motor relay 15.Coolant temperature warning light 16.Fuel level warning light 17.Engine trouble warning light 18.Starter relay 19.FI diagnostic tool 20.Crankshaft position sensor 21.Intake air pressure sensor 22.Throttle position sensor 23.ISC (idle speed control) valve 24.Intake air temperature sensor 25.Air filter case A. Fuel system B. Air system C. Control system

IMPORTANT INFORMATION 1-4 EAS20180 IMPORTANT INFORMATION EAS20190 PREPARATION FOR REMOVAL AND DISAS- SEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” on page 1-7. 3. When disassembling, always keep mated parts together. This includes gears, cylin- ders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. EAS20210 GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket sur- faces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease. EAS20220 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates “1” and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. 1. Oil 2. Lip 3. Spring 4. Grease

YAMAHA YFZ450R YFZ450 ATV Service Repair Manual 2009-2013

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