maintenance YAMAHA YZ450F 2014 User Guide

MAINTENANCE INTERVALS
3-6
LEVERS
Adjust clutch lever
free play
KICKSTARTER LE-
VER, BRAKE PED-
AL, FOOTREST
Lubricate
OUTSIDE NUTS
AND BOLTS
RetightenRefer to “TORQUE-CHECK
POINTS” on page 1-25.
ITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks

PRE-OPERATION INSPECTION AND MAINTENANCE
3-7
EAS1SL1067
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating
condition.
Before using this machine, check the following points.
EAS1SL1068GENERAL INSPECTION AND MAINTENANCE
TIP
Perform usual maintenance enough so that, in the race course, a confirmation of that and simple set-
ting adjustments may only be left, in order to get enough time to use effectively.
ITEMinspectPage
CoolantCheck that coolant is filled up to the radiator cap.
Check the cooling system for leakage.3-8 – 10
FuelCheck that a fresh gasoline is filled in the fuel tank.
Check the fuel line for leakage.1-22
Engine oilCheck that the oil level is correct. Check the crank-
case and oil line for leakage.3-14 – 16
Gear shifter and clutchCheck that gears can be shifted correctly in order and
that the clutch operates smoothly.3-10 – 11
Throttle grip/Housing
Check that the throttle grip operation and free play
are correctly adjusted. Lubricate the throttle grip and
housing, if necessary.
3-11 – 12
BrakesCheck the play of front brake and effect of front and
rear brake.3-21 – 27
Drive chainCheck drive chain slack and alignment. Check that
the drive chain is lubricated properly.3-27
4-64 – 65
WheelsCheck for excessive wear and tire pressure. Check
for loose spokes and have no excessive play.3-32 – 33
SteeringCheck that the handlebar can be turned smoothly and
have no excessive play.3-33 – 34
Front forks and rear
shock absorberCheck that they operate smoothly and there is no oil
leakage.3-28 – 32
Cables (wires)
Check that the clutch and throttle cables move
smoothly. Check that they are not caught when the
handlebars are turned or when the front forks travel
up and down.
—
Exhaust pipeCheck that the exhaust pipe is tightly mounted and
has no cracks.3-13 – 14
Rear wheel sprocketCheck that the rear wheel sprocket tightening bolt is
not loose.4-8 – 9
LubricationCheck for smooth operation. Lubricate if necessary. 3-12 , 3-34
Bolts and nutsCheck the chassis and engine for loose bolts and
nuts.1-25 – 26
Lead connectorsCheck that the AC magneto, ECU and ignition coil are
connected tightly.1-12 – 14
Settings
Is the machine set suitably for the condition of the rac-
ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?10-1 – 8

FUEL INJECTION SYSTEM
8-12
YAMAHA DIAGNOSTIC TOOL
This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.
FEATURES OF THE YAMAHA DIAGNOSTIC TOOL
A diagnosis can be made more quickly than traditional methods with the Yamaha diagnostic tool.
Using this software, ECU and sensor data, as well as fault diagnosis, vehicle maintenance, and any
necessary information can be recorded and displayed on your computer screen through a USB
adapter connected to the computer interface with a communication cable connected to the vehicle's
ECU.
Data obtained in various functions can be saved as vehicle history, and can be accumulated.
FUNCTIONS OF THE YAMAHA DIAGNOSTIC TOOL
However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as
adjusting the ignition timing.
CONNECTING THE YAMAHA DIAGNOSTIC TOOL
1. Remove the coupler for connecting setting tool.
Yamaha diagnostic tool
90890-03215
Fault diagnosis modeFault codes recorded on the ECU are read, and the con-
tents are displayed.
Function diagnostic modeCheck the operation of the output value of each sensor
and actuator.
Inspection modeDetermine whether each sensor or actuator is functioning
properly.
CO adjustment modeAdjust the concentration of CO admissions during idling.
Monitoring modeDisplays a graph of sensor output values for actual oper-
ating conditions.
Logging modeRecords and saves the sensor output value in actual driv-
ing conditions.
View logDisplays the logging data.
ECU rewriteIf necessary, the ECU is rewritten using the ECU rewrite
data provided by Yamaha. Ignition timing adjustment, etc.
cannot be changed from the vehicle's original state.

FUEL INJECTION SYSTEM
8-14
Fault code12
SymptomCrankshaft position sensor: no normal signals are received
from the crankshaft position sensor.
Fail-safe systemUnable to start engine
Unable to drive vehicle
Diagnostic code No.—
Diagnostic tool display—
Procedure—
Or-
der
Probable cause of malfunc-
tion and checkMaintenance jobReinstatement method
1Connection of crankshaft po-
sition sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Crank the engine.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
2Connection of wire harness
ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Crank the engine.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
3Wire harness continuity.Open or short circuit  Re-
place the wire harness.
Between the crankshaft posi-
tion sensor coupler and ECU
coupler.
gray–gray
black/blue–black/blue
Crank the engine.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
4Mounted condition of crank-
shaft position sensor.
Check for looseness or
pinching.
Check the gap between the
crankshaft position sensor
and the pickup rotor.
Improperly mounted sensor
 Remount or replace the
sensor.
“AC MAGNETO” on
page 5-59.
Crank the engine.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
5Defective crankshaft position
sensor.Check the crankshaft position
sensor.
“CHECKING THE CRANK-
SHAFT POSITION SEN-
SOR” on page 8-42.
Crank the engine.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
6Faulty ECUReplace the ECU.

FUEL INJECTION SYSTEM
8-15
TIP
If fault code Nos. 13 and 14 are both displayed, perform checkup and repair jobs for fault code No.
13 first.
Fault code13
SymptomIntake air pressure sensor: open or short circuit detected.
Fail-safe systemAble to start engine
Able to drive vehicle
Diagnostic code No.03
Diagnostic tool displayDisplays the intake air pressure.
ProcedureThe atmospheric pressure is displayed on the Yamaha diagnostic
tool.
Or-
der
Probable cause of malfunc-
tion and checkMaintenance jobReinstatement method
1Connection of intake air pres-
sure sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
2Connection of wire harness
ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
3Connection of sub wire har-
ness coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the sub-
wire harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
4Wire harness continuity.Open or short circuit  Re-
place the wire harness.
Between intake air pressure
sensor coupler and ECU cou
-
pler.
pink/black–pink/black
blue–blue
black/blue–black/blue
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
5Mounted condition of intake
air pressure sensor.
Check for looseness or
pinching.
Check the mounted position
for correctness.
Improperly mounted sensor
 Remount or replace the
sensor.Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.

FUEL INJECTION SYSTEM
8-16
TIP
If fault code Nos. 13 and 14 are both displayed, perform checkup and repair jobs for fault code No.
13 first.
6Defective intake air pressure
sensor.Execute the diagnostic mode.
(Code No.03)
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
0 m above sea level: About
101 kPa
1000 m above sea level:
About 90 kPa
2000 m above sea level:
About 80 kPa
3000 m above sea level:
About 70 kPa
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
7Faulty ECUReplace the ECU.
Fault code14
SymptomIntake air pressure sensor: hose system malfunction (clogged
or detached hose)
Fail-safe systemAble to start engine
Able to drive vehicle
Diagnostic code No.03
Diagnostic tool displayDisplays the intake air pressure.
ProcedureThe atmospheric pressure is displayed on the Yamaha diagnostic
tool.
Or-
der
Probable cause of malfunc-
tion and checkMaintenance jobReinstatement method
1The intake air pressure sen-
sor hose is damaged, discon-
nected, clogged, twisted or
bent.
Repair or replace the sensor
hose.After starting the engine, idle
this and wait about 5 sec
-
onds.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
Fault code 13
Symptom Intake air pressure sensor: open or short circuit detected.

FUEL INJECTION SYSTEM
8-17
2Defective intake air pressure
sensor.Execute the diagnostic mode.
(Code No. 03)
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
0 m above sea level: About
101 kPa
1000 m above sea level:
About 90 kPa
2000 m above sea level:
About 80 kPa
3000 m above sea level:
About 70 kPa
Fault code15
SymptomThrottle position sensor: open or short circuit detected.
Fail-safe systemAble to start engine
Able to drive vehicle
Diagnostic code No.01
Diagnostic tool displayDisplays the throttle angle.
• 11–14 (throttle in fully closed position)
• 109–116 (throttle in fully opened position)
ProcedureCheck with throttle valves fully closed.
Check with throttle valves fully opened.
Or-
der
Probable cause of malfunc-
tion and checkMaintenance jobReinstatement method
1Connection of throttle posi-
tion sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
2Connection of wire harness
ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
Fault code 14
SymptomIntake air pressure sensor: hose system malfunction (clogged
or detached hose)

FUEL INJECTION SYSTEM
8-19
Fault code16
SymptomThrottle position sensor: stuck throttle position sensor is de-
tected.
Fail-safe systemAble to start engine
Able to drive vehicle
Diagnostic code No.01
Diagnostic tool displayDisplays the throttle angle.
• 11–14 (throttle in fully closed position)
• 109–116 (throttle in fully opened position)
ProcedureCheck with throttle valves fully closed.
Check with throttle valves fully opened.
Or-
der
Probable cause of malfunc-
tion and checkMaintenance jobReinstatement method
1Mounted condition of throttle
position sensor.
Check for looseness or
pinching.
Check the mounted condition
for correctness.
Improperly mounted sensor
 Remount or replace the
sensor.
Refer to “ADJUSTING THE
THROTTLE POSITION SEN-
SOR” on page 7-9.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
2Defective throttle position
sensor.Execute the diagnostic mode.
(Code No. d:01)
When the throttle is fully
closed, 11–14 displays.
When the throttle is fully
opened, 109–116 displays.
Incorrect display range 
Replace the throttle position
sensor.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
3Faulty ECUReplace the ECU.

FUEL INJECTION SYSTEM
8-20
TIP
Make sure that the machine is completely cold before checking the coolant temperature sensor.
Fault code21
SymptomCoolant temperature sensor: open or short circuit detected.
Fail-safe systemAble to start engine
Able to drive vehicle
Diagnostic code No.06
Diagnostic tool displayDisplays the coolant temperature.
ProcedureCompare the actually measured coolant temperature with the
Yamaha diagnostic tool display value.
Or-
der
Probable cause of malfunc-
tion and checkMaintenance jobReinstatement method
1Connection of coolant tem-
perature sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
2Connection of wire harness
ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
3Wire harness continuity.Open or short circuit  Re-
place the wire harness.
Between coolant temperature
sensor coupler and ECU cou
-
pler.
green/white–green/white
black/blue–black/blue
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
4Mounted condition of coolant
temperature sensor.
Check for looseness or
pinching.
Check the mounted condition
for correctness.
Improperly mounted sensor
 Remount or replace the
sensor.Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
5Defective coolant tempera-
ture sensor.
Execute the diagnostic mode.
(Code No. 06)
When the machine is cold,
displayed temperature is
close to the ambient temper
-
ature.
Improper display  Replace
the coolant temperature sen
-
sor.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
6Faulty ECUReplace the ECU.

FUEL INJECTION SYSTEM
8-21
TIP
Make sure that the machine is completely cold before checking the intake air temperature sensor.
Fault code22
SymptomIntake air temperature sensor: open or short circuit detected.
Fail-safe systemAble to start engine
Able to drive vehicle
Diagnostic code No.05
Diagnostic tool displayDisplays the intake air temperature.
ProcedureCompare the actually measured intake air temperature with the
Yamaha diagnostic tool display value.
Or-
der
Probable cause of malfunc-
tion and checkMaintenance jobReinstatement method
1Connection of intake air tem-
perature sensor coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
2Connection of wire harness
ECU coupler.
Check the locking condition
of the coupler.
Disconnect the coupler, and
check the pins (for bent or
broken terminals and locking
condition of the pins).
Improperly connected 
Connect the coupler secure
-
ly, or repair/replace the wire
harness.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
3Wire harness continuity.Open or short circuit  Re-
place the wire harness.
Between intake air tempera-
ture sensor coupler and ECU
coupler.
brown/white–brown/white
black/blue–black/blue
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
4Mounted condition of intake
air temperature sensor.
Check for looseness or
pinching.
Check the mounted condition
for correctness.
Improperly mounted sensor
 Remount or replace the
sensor.Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
5Defective intake air tempera-
ture sensor.
Execute the diagnostic mode.
(Code No. 05)
When the machine is cold,
displayed temperature is
close to the ambient temper
-
ature.
Improper display  Replace
the intake air temperature
sensor.
Turn “ON” the switch on the
FI diagnostic tool sub-lead.
Fault code No. is not dis-
played  Repair is finished.
Fault code No. is displayed 
Go to next order.
6Faulty ECUReplace the ECU.