YAMAHA YZ450F 2014 Manual Online

CABLE ROUTING DIAGRAM
2-38
1. Throttle cable
2. Clutch cable3. Engine stop switch lead
4. Cable guide
5. Head pipe6. Front brake hose
7. Brake hose guide
8. Number plate
A. Number plate band
B. Pass the clutch cable to the rear of the number
plate band.
C. Clamp the engine stop switch lead to the handle-bar by the plastic band. Do not cut the end of the
plastic band.
D. Pass the engine stop switch lead between the
head pipe and the cable guide.
E. Pass the front brake hose to the front of the num-ber plate.
F. 40°±10°G. Vertical direction
H. Pass the engine stop switch lead under the han-dlebar.
I. Pass the clutch cable to the guide in the number
plate.

CABLE ROUTING DIAGRAM
2-39

CABLE ROUTING DIAGRAM
2-40
1. Main harness
2. Radiator3. Throttle position sensor lead
4. Joint coupler
5. Intake air temperature sensor lead6. Intake air pressure sensor lead
7. Frame
8. Fuel hose9. High tension cord
10. Spark plug cap
11. Cylinder head cover12. Sub-wire harness
13. Injector coupler
14. Injector lead15. Throttle body
16. Air filter case
17. ECU18. Sub-wire harness coupler
A. Fix the main harness by the plastic clamp, and in-sert the projection of the plastic clamp into the
hole in the sheet metal of the radiator.
B. Insert the projection of the main harness into the
hole in the frame.
C. To the sub-wire harness
D. Pass the high tension cord above the fuel hose.
E. ±10°F. Install the spark plug cap with this facing the right
of the vehicle.
G. Push the spark plug cap home, where there shall
be no gap between it and the cylinder head cover.
H. Pass the injector lead to the top of the vehicle be-yond the fuel hose.I. Insert the coupler of the sub-wire harness into the
rib of the air filter case.
J. Pass the sub-wire harness between the ECU and
the air filter case.

CABLE ROUTING DIAGRAM
2-41

CABLE ROUTING DIAGRAM
2-42
1. Brake master cylinder
2. Brake hose holder3. Brake hoses
A. While installing the brake hose, direct a bend in
its pipe portion as shown, and bring it into contact
with the projection on the brake caliper.
B. Pass the brake hose into the brake hose holders.C. If the brake hose interferes with the rear shock
absorber, correct its twist.
D. While installing the brake hose, direct a bend in
its pipe portion as shown, and bring it into contact
with the projection on the brake master cylinder.

CABLE ROUTING DIAGRAM
2-43

3
PERIODIC CHECKS AND ADJUSTMENTS
MAINTENANCE INTERVALS.......................................................................... 3-1
MAINTENANCE INTERVALS .................................................................... 3-1
PRE-OPERATION INSPECTION AND MAINTENANCE................................. 3-7
GENERAL INSPECTION AND MAINTENANCE........................................ 3-7
ENGINE............................................................................................................ 3-8
CHECKING THE COOLANT LEVEL .......................................................... 3-8
CHECKING THE COOLING SYSTEM ....................................................... 3-8
CHANGING THE COOLANT...................................................................... 3-8
CHECKING THE RADIATOR CAP ............................................................ 3-9
CHECKING THE RADIATOR CAP OPENING PRESSURE ...................... 3-9
CHECKING THE COOLANT CIRCULATORY SYSTEM FOR LEAKS .... 3-10
ADJUSTING THE CLUTCH LEVER POSITION ...................................... 3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................... 3-10
ADJUSTING THE THROTTLE GRIP FREE PLAY .................................. 3-11
LUBRICATING THE THROTTLE CABLE ................................................ 3-12
CLEANING THE AIR FILTER ELEMENT................................................. 3-12
CHECKING THE THROTTLE BODY JOINT ............................................ 3-13
CHECKING THE BREATHER HOSES .................................................... 3-13
CHECKING THE EXHAUST SYSTEM..................................................... 3-13
CHECKING THE FUEL LINE ................................................................... 3-14
CHECKING THE ENGINE OIL LEVEL..................................................... 3-14
CHANGING THE ENGINE OIL ................................................................ 3-15
ADJUSTING THE ENGINE IDLING SPEED ............................................ 3-16
ADJUSTING THE VALVE CLEARANCE ................................................. 3-17
CHASSIS........................................................................................................ 3-21
BLEEDING THE BRAKE SYSTEM .......................................................... 3-21
CHECKING THE BRAKE HOSE .............................................................. 3-22
ADJUSTING THE FRONT BRAKE .......................................................... 3-22
ADJUSTING THE REAR BRAKE ............................................................. 3-23
CHECKING THE FRONT BRAKE PADS ................................................. 3-23
CHECKING THE REAR BRAKE PADS ................................................... 3-25
CHECKING THE REAR BRAKE PAD INSULATOR ................................ 3-26
CHECKING THE BRAKE FLUID LEVEL.................................................. 3-26
ADJUSTING THE DRIVE CHAIN SLACK ................................................ 3-27
CHECKING THE FRONT FORK LEGS ................................................... 3-28
CHECKING THE FRONT FORK PROTECTOR GUIDE .......................... 3-28
CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL ................ 3-28
AIR BLEEDING FROM FRONT FORK .................................................... 3-28
ADJUSTING THE FRONT FORK LEGS .................................................. 3-29
CHECKING THE SWINGARM OPERATION ........................................... 3-30
CHECKING THE REAR SUSPENSION ................................................... 3-30
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-30
CHECKING THE TIRES ........................................................................... 3-32
CHECKING AND TIGHTENING THE SPOKES ....................................... 3-32
CHECKING THE WHEELS ...................................................................... 3-33

CHECKING THE WHEEL BEARINGS ..................................................... 3-33
CHECKING AND ADJUSTING THE STEERING HEAD .......................... 3-33
LUBRICATING THE LEVERS .................................................................. 3-34
LUBRICATING THE PEDAL .................................................................... 3-34
ELECTRICAL SYSTEM.................................................................................. 3-35
CHECKING THE SPARK PLUG .............................................................. 3-35
CHECKING THE IGNITION TIMING ........................................................ 3-35

MAINTENANCE INTERVALS
3-1
EAS1SL1065
MAINTENANCE INTERVALS
EAS1SL1066MAINTENANCE INTERVALSECA@
NOTICE
• After a break-in or before each race, always check the points shown in “TORQUE-CHECK
POINTS” for tightening torques and retighten them. (
“TORQUE-CHECK POINTS” on page 1-
25.)
• Periodic inspection is essential in making full use of the machine performance. The life of
parts varies significantly according to the environment in which the machine runs (e.g., rain,
dirt, etc.). Therefore, earlier inspection is required by reference to the list below.
ITEM
After
break-
in
Every
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)
As re-
quiredRemarks
VALVE
Check the valve
clearancesThe engine must be cold.
InspectCheck the valve seats and the
valve faces for wear.
Replace
VALVE SPRING
InspectCheck the free length and the
tilt.
Replace
VALVE LIFTER
InspectCheck for scratches and wear.
Replace
CAMSHAFTInspect the camshaft surface.
InspectInspect the decompression
system.
Replace
CAMSHAFT
SPROCKET
InspectCheck for wear on the teeth
and for damage.
Replace
PISTON
InspectInspect crack.
CleanInspect carbon deposits and
eliminate them.
ReplaceReplace the piston, piston pin,
piston pin clip, and piston ring
all as a set.

MAINTENANCE INTERVALS
3-2
PISTON RING
InspectCheck the end gap of the pis-
ton ring.
ReplaceReplace the piston, piston pin,
piston pin clip, and piston ring
all as a set.
PISTON PIN
Inspect
ReplaceReplace the piston, piston pin,
piston pin clip, and piston ring
all as a set.
CYLINDER HEADCheck the coolant passages
for corrosion.

Inspect carbon deposits and
eliminate them.
Inspect and cleanCheck for warpage, and re-
place the gasket.
CYLINDER
Inspect and cleanInspect score marks.
ReplaceInspect wear.
ENGINE OIL
InspectCheck the engine oil amount.
Replace
OIL FILTER ELE-
MENT
Replace
OIL STRAINER
Clean
CLUTCH
Inspect and adjustInspect housing, friction plate,
clutch plate and spring.
Replace
TRANSMISSION
Inspect
Replace bearings
SHIFT FORK, SHIFT
CAM, GUIDE BAR
InspectInspect wear.
ITEMAfter
break-
inEvery
race
(about
2.5
hours)Every
third
(about
7.5
hours)Every
fifth
(about
12.5
hours)As re-
quiredRemarks