YAMAHA YZ450F 2016 Owners Manual

9
TROUBLESHOOTING
TROUBLESHOOTING...................................................................................... 9-1
GENERAL INFORMATION ........................................................................ 9-1
STARTING FAILURES ............................................................................... 9-1
INCORRECT ENGINE IDLING SPEED ..................................................... 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ............................ 9-2
SHIFTING IS DIFFICULT ........................................................................... 9-2
SHIFT PEDAL DOES NOT MOVE ............................................................. 9-2
JUMPS OUT OF GEAR.............................................................................. 9-2
CLUTCH SLIPS .......................................................................................... 9-2
CLUTCH DRAGS ....................................................................................... 9-2
OVERHEATING ......................................................................................... 9-2
OVERCOOLING ......................................................................................... 9-3
POOR BRAKING PERFORMANCE ........................................................... 9-3
FRONT FORK OIL LEAKING ..................................................................... 9-3
FAULTY FRONT FORK LEGS ................................................................... 9-3
UNSTABLE HANDLING ............................................................................. 9-3
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS............................. 9-4

TROUBLESHOOTING
9-1
EASB111348
TROUBLESHOOTING
EASB111349GENERAL INFORMATION
TIP
The following guide for troubleshooting does
not cover all the possible causes of trouble. It
should be helpful, however, as a guide to basic
troubleshooting. Refer to the relative procedure
in this manual for checks, adjustments, and re-
placement of parts.
EASB111350STARTING FAILURES
Engine
1. Cylinder and cylinder head
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder head gasket
• Damaged cylinder gasket
• Worn or damaged cylinder
• Incorrect valve clearance
• Improperly sealed valve
• Incorrect valve-to-valve-seat contact
• Incorrect valve timing
• Faulty valve spring
• Seized valve
2. Piston and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
3. Air filter
• Improperly installed air filter
• Clogged air filter element
4. Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
Fuel system
1. Fuel tank
• Empty fuel tank
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel
• Clogged or damaged fuel hose
2. Fuel pump
• Faulty fuel pump
3. Throttle body
• Deteriorated or contaminated fuel
• Sucked-in airElectrical system
1. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
2. Ignition coil
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary
coils
3. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
4. Switches and wiring
• Faulty ECU
• Faulty engine stop switch
• Broken or shorted wiring
• Faulty neutral switch
• Improperly grounded circuit
• Loose connections
EASB111351INCORRECT ENGINE IDLING SPEED
Engine
1. Cylinder and cylinder head
• Incorrect valve clearance
• Damaged valve train components
2. Air filter
• Clogged air filter element
Fuel system
1. Throttle body
• Damaged or loose throttle body joint
• Improperly synchronized throttle bodies
• Improper throttle cable free play
• Flooded throttle body
Electrical system
1. Spark plug
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
2. Ignition coil
• Broken or shorted primary or secondary
coils
• Cracked or broken ignition coil

TROUBLESHOOTING
9-2
3. Ignition system
• Faulty ECU
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key
EASB111352POOR 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
EASB111353SHIFTING IS DIFFICULT
Refer to “CLUTCH” on page 5-38.
EASB111354SHIFT PEDAL DOES NOT MOVE
Engine
1. Shift shaft
• Bent shift shaft
2. Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
3. Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
EASB111355JUMPS OUT OF GEAR
Engine
1. Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
2. Shift forks
• Worn shift fork
3. Shift drum
• Incorrect axial play
• Worn shift drum groove
4. Transmission
• Worn gear dog
EASB111356
CLUTCH SLIPS
Engine
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
EASB111357CLUTCH DRAGS
Engine
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
EASB111358OVERHEATING
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

TROUBLESHOOTING
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
EASB111359OVERCOOLING
Cooling system
1. Coolant temperature sensor
• Faulty coolant temperature sensor
EASB111360POOR BRAKING PERFORMANCE
Chassis
1. Brake(s)
• 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
EASB111361FRONT FORK OIL LEAKING
Chassis
1. Front fork
• 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
EASB111362FAULTY FRONT FORK LEGS
Chassis
1. Front fork
• Bent or damaged inner tube
• Bent or damaged outer tube
• Broken fork spring
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EASB111363UNSTABLE HANDLING
Chassis
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

LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
9-4
EASB111364
LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
LIST OF DIAGNOSTIC CODES
COMMUNICATION ERROR WITH YAMAHA DIAGNOSTIC TOOLFault
codeITEM Page
12 Crankshaft position sensor: no normal signals are received from the
crankshaft position sensor.8-14
13 Intake air pressure sensor: open or short circuit detected. 8-15
14 Intake air pressure sensor: hose system malfunction (clogged or de-
tached hose)8-16
15 Throttle position sensor: open or short circuit detected. 8-17
16 Throttle position sensor: stuck throttle position sensor is detected. 8-19
21 Coolant temperature sensor: open or short circuit detected. 8-20
22 Intake air temperature sensor: open or short circuit detected. 8-21
30 The vehicle has overturned. 8-22
33 Ignition coil: open or short circuit detected in the primary lead of the
ignition coil.8-23
39 Injector: open or short circuit detected. 8-24
41 ECU: built-in lean angle sensor malfunction 8-25
44 EEPROM fault code No.: an error is detected while reading or writing
on EEPROM.8-26
46 Vehicle system power supply: normal voltage is not supplied to the
ECU.8-27
50 ECU: faulty ECU memory 8-28
Fault
codeITEM Page
Waiting
for con-
nectionNo communication signal is received from the ECU.
8-28
Er-2 Signals from the ECU cannot be received within the specified period
of time.8-29
Er-3 Data from the ECU cannot be received correctly. 8-30
Er-4 Registered data cannot be received from the Yamaha diagnostic tool. 8-31

LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
9-5
SENSOR OPERATION TABLE
Diag-
nostic
code
No.ITEM Display Procedure
01 Throttle angle
• Fully closed position
• Fully opened positionDisplays the throttle angle.
• 11–14
• 109–116• Check with throttle fully
closed.
• Check with throttle fully
opened.
03 Pressure of suction pipe Displays the intake air pres-
sure.The atmospheric pressure
is displayed on the Yamaha
diagnostic tool.
05 Intake air temperature Displays the intake air tem-
perature.Compare the actually mea-
sured intake air tempera-
ture with the Yamaha
diagnostic tool display val-
ue.
06 Coolant temperature Displays the coolant temper-
ature.Compare the actually mea-
sured coolant temperature
with the Yamaha diagnostic
tool display value.
08 Lean angle sensor
• Upright
•OverturnDisplays the output voltage.
• 1.0 (V)
• 4.0 (V)Remove the ECU, and in-
cline it 45 ° or more.
09 Monitor voltage Displays the voltage of the
external battery connected to
the Yamaha diagnostic tool.
• Approximately 12.0 (V)—
21 Neutral switch
• Gear in neutral
• Gear not in neutral•ON
•OFFOperate the shift pedal.
25 Gear position switch
• Gear in 1st or 2nd
• Gear not in 1st or 2nd•ON
•OFFOperate the shift pedal.
60 EEPROM fault code No.
display
• No fault
• CO adjustment valve
• Power Tuner injection cor-
rection setting 0–8, or
Power Tuner ignition tim-
ing correction setting 0–8•00
•01
•07—
61 Malfunction history ( )
code No. display *1
• There is no history.
• There is some history.•00
• Other: Displays the fault
code of ( ).—

LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
9-6
*1: Symbols used in the explanations of the malfunction history
: Normal
: There is currently a malfunction or abnormal condition.
: A malfunction or abnormal condition occurred previously, but the affected system or component
is currently operating normally.
ACTUATOR OPERATION TABLE62 Malfunction history ( )
code No. erasure *1
• There is no history.
• There is some history.•00
• Other: Displays the total
number of ( ) and ( ).Replace all ( ) with ( )
by the operation start pro-
cessing.
64 Setting history display
• There is no history.
• There is some history.
• History is unknown (Histo-
ry data is damaged).Displays the presence or ab-
sence of the setting history by
Power Tuner.
•00
•01
•02—
65 Setting map erasure
• There is no setting.
• There is some setting.Displays the presence or ab-
sence of the setting history by
Power Tuner.
•00
•01Erase all setting maps by
the operation start process-
ing.
70 Program version number Displays a program version
No.—
Diag-
nostic
code
No.ITEM Actuation Procedure
30 Ignition coil Actuates the ignition coil five
times at one-second inter-
vals.
“WARNING” on the Yamaha
diagnostic tool blinks five
times when the ignition coil is
actuated.Check that a spark is gener-
ated five times.
• Connect an ignition
checker.
36 Injector Actuates the injector five
times at one-second inter-
vals.
“WARNING” on the Yamaha
diagnostic tool blinks five
times when the injector is ac-
tuated.TIP: Before performing
this operation, be sure to
disconnect the fuel pump
coupler.
Check that injector is actu-
ated five times by listening
for the operating sound. Diag-
nostic
code
No.ITEM Display Procedure

LIST OF SELF-DIAGNOSTIC AND FAIL-SAFE ACTIONS
9-7

10
TUNING
CHASSIS........................................................................................................ 10-1
SELECTION OF THE SECONDARY REDUCTION RATIO
(SPROCKET) .......................................................................................... 10-1
DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS ................ 10-1
TIRE PRESSURE..................................................................................... 10-2
FRONT FORK SETTING.......................................................................... 10-2
CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL.......... 10-2
SETTING OF SPRING AFTER REPLACEMENT .................................... 10-3
FRONT FORK SETTING PARTS............................................................. 10-3
REAR SUSPENSION SETTING .............................................................. 10-3
CHOOSING SET LENGTH ...................................................................... 10-3
SETTING OF SPRING AFTER REPLACEMENT .................................... 10-4
REAR SHOCK ABSORBER SETTING PARTS ....................................... 10-5
SUSPENSION SETTING (FRONT FORK)............................................... 10-6
SUSPENSION SETTING (REAR SHOCK ABSORBER) ......................... 10-7

CHASSIS
10-1
EASB111366
CHASSIS
EASB111367SELECTION OF THE SECONDARY REDUC-
TION RATIO (SPROCKET)
<Requirement for selection of secondary gear
reduction ratio>
• It is generally said that the secondary gear ra-
tio should be reduced for a longer straight por-
tion of a speed course and should be
increased for a course with many corners. Ac-
tually, however, as the speed depends on the
ground condition of the day of the race, be
sure to run through the circuit to set the ma-
chine suitable for the entire course.
• In actuality, it is very difficult to achieve set-
tings suitable for the entire course and some
settings may be sacrificed. Thus, the settings
should be matched to the portion of the
course that has the greatest effect on the race
result. In such a case, run through the entire
course while making notes of lap times to find
the best balance; then, determine the second-
ary reduction ratio.
• If a course has a long straight portion where a
machine can run at maximum speed, the ma-
chine is generally set such that it can develop
its maximum revolutions toward the end of the
straight line, with care taken to avoid the en-
gine over-revving.
TIP
Riding technique varies from rider to rider and
the performance of a machine also vary from
machine to machine. Therefore, do not imitate
other rider’s settings from the beginning but
choose your own setting according to the level
of your riding technique.
EASB111368
DRIVE AND REAR WHEEL SPROCKETS
SETTING PARTS
Secondary reduction ratio = Number of
rear wheel sprocket teeth/Number of
drive sprocket teeth
Secondary reduction ratio
3.692 (48/13)
Part name Type Part number
Drive sprocket “1”
(STD) 13T 9383E-13233
Rear wheel
sprocket “2” 47T 17D-25447-50
(STD) 48T 17D-25448-50
49T 17D-25449-50
50T 17D-25450-50
51T 17D-25451-50
52T 17D-25452-50