check engine YAMAHA YZ450F 2014 Owners Manual

EAS1SL1005
SAFETY INFORMATION
THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road
use on public lands may also be illegal. Please check local regulations before riding.
• THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at maximum power until you are totally familiar with its char-
acteristics.
• THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this machine.
• ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an approved helmet with goggles or a face shield. Also
wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not
be caught in any of the moving parts or controls of the machine.
• ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER.
For safety and reliability, the machine must be properly maintained. Always perform the pre-oper-
ation checks indicated in this manual.
Correcting a mechanical problem before you ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or ex-
haust system. Never refuel in the vicinity of an open flame, or while smoking.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get
into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, imme
-
diately wash skin areas with soap and water, and change your clothes.
• ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are
poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Car
-
bon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.
• PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE.
Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope
or soft ground as it may fall over.
• THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE EN-
GINE HAS BEEN RUN.
Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
For safety, drain the gasoline from the fuel tank before transporting the vehicle.

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TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND ADJUST-
MENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
TROUBLE SHOOTING
TUNING

STARTING AND BREAK-IN.......................................................................... 1-22
FUEL ........................................................................................................ 1-22
STARTING A COLD ENGINE .................................................................. 1-22
STARTING A WARM ENGINE ................................................................. 1-23
BREAK-IN PROCEDURES ...................................................................... 1-23
MAINTENANCE AFTER BREAK-IN.............................................................. 1-24
MAJOR MAINTENANCE .......................................................................... 1-24
TORQUE-CHECK POINTS............................................................................ 1-25
CLEANING AND STORAGE.......................................................................... 1-27
CLEANING ............................................................................................... 1-27
STORAGE ................................................................................................ 1-27

DESCRIPTION
1-4
EAS1SL1009
DESCRIPTION
TIP
Designs and specifications of the vehicle are subject to change without notice. Therefore, please
note that the descriptions in this manual may be different from those for the vehicle you have pur
-
chased.
1. Clutch lever10. Coolant drain bolt
2. Front brake lever11. Rear brake pedal
3. Throttle grip12. Air filter
4. Radiator cap13. Drive chain
5. Fuel tank cap14. Shift pedal
6. Engine stop switch15. Oil level check window
7. Fuel tank16. Starter knob/idle screw
8. Kickstarter lever17. Front fork
9. Radiator
2 1
6
78 954 3
11 10 17 16 15 14 1312

IMPORTANT INFORMATION
1-10
EAS20180
IMPORTANT INFORMATION
EAS1SL1023PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
1. Before the jobs, completely remove mud,
dust, and the like in order to prevent the en
-
try of them into the inside during the jobs.
• Before cleaning with high-pressure water of
washers, cover the following parts.

Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Hole under the water pump housing
2. Use proper special tools and equipment.
See “SPECIAL TOOLS.”
3. During disassembly, check and measure the
required parts, and make a record of them
so that you may refer to the record when in
-
stalling them. Moreover, arrange gears, cyl-
inders, pistons, and other parts for each
section so as not to confuse or lose them.
4. During disassembly, clean each of the parts,
and store them in trays for each section.
5. Flammable. Keep servicing areas away
from any source of fire.
6. During servicing, take special care not to re-
ceive an injury or a burn on the engine, the
exhaust pipe, the silencer, or the like.
7. If coolant is left adhered to the chassis, paint
and plating will be damaged. Therefore,
rinse it out with water in good time.
EWA
WARNING
Coolant is potentially harmful and should
be handled with special care.
• If it enters your eyes, wash it away with wa-
ter enough and then get medical attention
• If it splashes on your skin or clothes,
quickly wash it away with water and then
with soapy water.
• If it is swallowed, immediately induce vom-
iting and get medical attention.
EAS1SL1024REPLACEMENT PARTS
Make sure that the parts and grease or oil to be
used for repair of the vehicle, including periodic
replacement parts, are new YAMAHA genuine
parts and recommended parts.
Do not use any used parts, because these may
not be genuine though they have similar ap
-
pearances or because the quality may be
changed by aging.
EAS1SL1025

SPECIAL TOOLS
1-19
Crankcase separating tool
90890-04152
YU-A9642
This tool is used to remove
the crankshaft.
Ignition checker
90890-06754
Oppama pet-4000 spark
checker
YM-34487
This tool is used to check the
spark performance of the ig
-
nition coil.
Digital tachometer
90890-06760
YU-39951-B
This tool is used to measure
the engine speed.
Three bond No.1215®
90890-85505
This sealant (Bond) is used
for crankcase mating sur
-
face, etc.
Tool name/Part number How to use Illustration

STARTING AND BREAK-IN
1-23
7. To stop the engine, push the engine stop
switch “1.”
TIP
Continue pushing the engine stop switch till the
engine comes to a full stop.
EAS1SL1044STARTING A WARM ENGINE
When the engine is warm, give a kick with the
throttle closed without using the starter knob/
idle screw.
TIP
If it fails to start, fully open the throttle grip and
give 10 to 20 slow kicks to clear the engine of
the rich air-fuel mixture retained in it.
EAS1SL1045BREAK-IN PROCEDURES
A break-in is important so that rotating portion,
sliding surfaces, and mounted areas may fit
one another, and that the rider may become ac
-
customed to the machine.ECA
NOTICE
Before running, do maintenance on the air
filter element.
Refer to “CLEANING THE AIR FILTER ELE-
MENT” on page 3-12.
1. After warming up the engine, drive it for
about 20 minutes at a throttle opening of 1/2
or less.
2. Make a pit stop, and check mounted areas
for looseness, oil leaks, or other problems.
3. Then, drive it for about 40 minutes at a throt-
tle opening of 3/4 or less.
4. Make a pit stop again, and thoroughly check
mounted areas for looseness, oil leaks, or
other problems. Thorough checks and ad
-
justments are required in particular for
stretch of cables, free play of the brake,
stretch of the drive chain, looseness of the
spoke, and so on.
ECA
NOTICE
After a break-in or after each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them. (
“TORQUE-CHECK
POINTS” on page 1-25) 
Also when the following parts are replaced,
a break-in is required.
• Cylinder and Crankshaft: A break-in is re-
quired for about an hour.
• Piston, Piston ring, Valve, Camshaft, and
Gear: A break-in is required for about 30
minutes at a throttle opening of 1/2 or less.
Observe the condition of the engine careful-
ly during a break-in. 
For checkpoints for a break-in, see “MAIN-
TENANCE AFTER BREAK-IN.” If any prob-
lem is found, immediately stop the engine
and make a checkup.
EAS1SL1046

MAINTENANCE AFTER BREAK-IN
1-24
MAINTENANCE AFTER BREAK-IN
After a break-in, perform careful maintenance
to get ready for the next practice or race.
Refer to “PRE-OPERATION INSPECTION
AND MAINTENANCE” on page 3-7.
EAS1SL1047MAJOR MAINTENANCE
1. For the engine
• Leaks around the engine
Check for pressure leaks from the cylinder
head or the cylinder, oil leaks from the
crankcase or the case cover, leaks from the
coolant system, and other leaks.
• Check that the valve, the cylinder head, the
cylinder, the piston, and the piston ring fit
one another, and that contact between the
valve and the cylinder head, and that be
-
tween the cylinder and the piston are cor-
rect.
• Engine oil change
Drain the oil, and check for dirt and foreign
materials such as metal chips. (If any foreign
material is mixed, disassemble and check
the crankcase.)
Pour the specified amount of the recom-
mended oil.
• AC magneto
Check for looseness in mounted areas of
the rotor and the stator.
Check that the connector is not being dis-
connected.
• Silencer
Check the main body and stay for cracks.
Check for leaks.
• Mounting bolts and nuts
Check for looseness in mounted areas of
parts, as well as engine mounting bolts and
engine brackets.
2. For the chassis
• Check welds and mounted areas of the
frame, the swingarm, the link, the bracket,
and so on, for looseness and cracks.
• Wheel (s)
Check the wheel for runout. Check the
spoke for looseness.
• Brake(s)
Check the brake disc mounting bolt for
looseness.
Check that the reservoir contains the speci-
fied amount of brake fluid. Check for leaks.
• Cable
Grease and adjust cables.
•Drive chain
Lubricate the drive chain and adjust its ten-
sion.
• Fuel tank
Clean the inside of the fuel tank. Check for
leaks.
• Suspension
Check for oil leaks in the front fork or the rear
shock absorber. Check that the mounted
conditions are good.
• Sprocket
Check for looseness in the sprocket mount-
ed on the rear wheel.
• Mounting bolts and nuts
Check mounted areas for looseness.JCA1SL1001
NOTICE
After a break-in or before each race, always
check the points shown in “TORQUE-
CHECK POINTS” for tightening torques and
retighten them. (Refer to
“TORQUE-CHECK
POINTS”.)
• Greasing and oiling
Always grease or oil the specified points.

TORQUE-CHECK POINTS
1-25
EAS1SL1048
TORQUE-CHECK POINTS
Frame constructionFrame to rear frame
Frame to engine protector
Combined seat and fuel tankFuel tank to frame
Engine mountingFrame to engine
Engine bracket to engine
Engine bracket to frame
SeatSeat to frame
SteeringSteering stem to handlebarSteering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
SuspensionFrontSteering stem to front forkFront fork to upper bracket
Front fork to lower bracket
RearLinkAssembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Mounting of rear shock absorberRear shock absorber and frame
Mounting of swingarmTightening of pivot shaft
Wheel (s)Mounting of wheelFrontTightening of wheel axle
Tightening of axle holder
Tightening of spoke nipple
RearTightening of wheel axle
Wheel to rear wheel sprocket
Tightening of spoke nipple
Brake(s)FrontBrake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handle-
bar
Tightening of bleed screw
Tightening of brake hose holder
RearBrake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Tightening of brake hose holder
Fuel systemFuel pump to fuel tank

TIGHTENING TORQUES
2-14
EAS1SL1057ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEMThread
sizeQ’tyTIGHTENING TORQUESRemarks
Camshaft cap boltM6810 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plugM12128 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plugM10113 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt (exhaust
pipe)M637 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head boltsM94See TIP.*1
Cylinder head boltsM6210 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover boltM6310 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage plug (cylinder head)M8115 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder boltM6110 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check boltM6210 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screwM6310 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nutM14150 Nm (5.0 m·kgf, 36 ft·lbf)
Use a
lock
washer.
Balancer nutM10145 Nm (4.5 m·kgf, 33 ft·lbf)
Use a
lock
washer.
Timing chain guide stopper plate
(exhaust side)M6110 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap boltM616 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner boltM6210 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain boltM6110 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screwM681.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator boltM6410 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt M6110 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt M6110 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump housing cover boltM6410 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump boltM525 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screwM412.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer boltM6110 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage cover bolt (left crank-
case)M6110 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover boltM513.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint boltM6210 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle body joint clamp boltM513.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter joint clamp boltM413.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air filter case boltM637 Nm (0.7 m·kgf, 5.1 ft·lbf)
LT
M
LT
LT
LT