ignition YAMAHA YZ450F 2015 User Guide

ENGINE REMOVAL
5-3
Removing the electronic parts
Order Part name Q’ty Remarks
Use a suitable stand to raise the front wheel
off the ground.
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left / right) Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case cover
1 Rectifier/regulator 1
2ECU 1
3 Ignition coil 1
4 Condenser 1
5 Neutral switch 1
6 AC magneto coupler 1 Disconnect.
7 Crankshaft position sensor coupler 1 Disconnect.
8 Coolant temperature sensor coupler 1 Disconnect.
For installation, reverse the removal proce-
dure.
T.R.
T.R.
T.R.T.R.
8 3
7
6
154
2
LT

THROTTLE BODY
7-5
EAS1SL5315
THROTTLE BODY
Removing the throttle body
Order Part name Q’ty Remarks
Seat Refer to “GENERAL CHASSIS” on page 4-1.
Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
Air scoop (left/right) Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
ECU Refer to “ENGINE REMOVAL” on page 5-1.
Ignition coil Refer to “ENGINE REMOVAL” on page 5-1.
1 Intake air temperature sensor coupler 1 Disconnect.
2 Air filter case 1
3 Fuel injector coupler 1 Disconnect.
4 Intake air pressure sensor coupler 1 Disconnect.
5 Throttle position sensor coupler 1 Disconnect.
6 Throttle cable cover 1
7 Throttle cable 2
8 Fuel hose 1
9 Exhaust pipe bracket 1
2
1
6
10
11
9
8
3
7
5
4
3.5 Nm (0.35 mkgf, 2.5 ftIbf)T.R
.
3.5 Nm (0.35 mkgf, 2.5 ftIbf)T.R
.
7 Nm (0.7 mkgf, 5.1 ftIbf)T.R.
3.0 Nm (0.30 mkgf, 2.2 ftIbf)T.R.
10 Nm (1.0 mkgf, 7.2 ftIbf)T.R.

8
ELECTRICAL SYSTEM
IGNITION SYSTEM.......................................................................................... 8-2
CIRCUIT DIAGRAM ................................................................................... 8-2
TROUBLESHOOTING ............................................................................... 8-4
CHARGING SYSTEM....................................................................................... 8-6
CIRCUIT DIAGRAM ................................................................................... 8-6
TROUBLESHOOTING ............................................................................... 8-8
FUEL INJECTION SYSTEM........................................................................... 8-10
CIRCUIT DIAGRAM ................................................................................. 8-10
YAMAHA DIAGNOSTIC TOOL ................................................................ 8-12
TROUBLESHOOTING DETAILS ............................................................. 8-13
FUEL PUMP SYSTEM.................................................................................... 8-32
CIRCUIT DIAGRAM ................................................................................. 8-32
TROUBLESHOOTING ............................................................................. 8-34
ELECTRICAL COMPONENTS....................................................................... 8-36
CHECKING THE SWITCHES .................................................................. 8-38
CHECKING THE IGNITION SPARK GAP................................................ 8-41
CHECKING THE SPARK PLUG CAP ...................................................... 8-41
CHECKING THE IGNITION COIL ............................................................ 8-41
CHECKING THE CRANKSHAFT POSITION SENSOR........................... 8-42
CHECKING THE ECU .............................................................................. 8-43
CHECKING THE STATOR COIL ............................................................. 8-43
CHECKING THE RECTIFIER/REGULATOR ........................................... 8-43
CHECKING THE COOLANT TEMPERATURE SENSOR........................ 8-44
CHECKING THE THROTTLE POSITION SENSOR ................................ 8-44
CHECKING THE THROTTLE POSITION SENSOR
INPUT VOLTAGE .................................................................................... 8-45
CHECKING THE INTAKE AIR PRESSURE SENSOR ............................ 8-46
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................... 8-46
CHECKING THE NEUTRAL SWITCH ..................................................... 8-46
CHECKING THE FUEL INJECTOR ......................................................... 8-47

IGNITION SYSTEM
8-2
EAS1SL5321
IGNITION SYSTEM
EAS1SL5322CIRCUIT DIAGRAM
B/L Gy
BR
A
A
AA
B
RR R R R R R
B
B
B RR
R
Lg
LgB/WB/Y
B/YB
B
BP
PP
Sb
B/LP/B
P/B
YL
YL
L
G/WBr/W
G/WBr/W
B/LB/L
B/L
B/L
B/R
B/R
R/B
R/B
O
OROR
OR
R
R
SbB
GyR
B/W P L B/L
B/L GyB/L B/L B/L B/L B/L LL PP BBBB
PP
Sb
RB
B/RR
R B
B/Y PSb
BB
RR/B
LYB/L
B/W RLg
B/LBr/W
B/L P/B LB/LG/W
BB/Y BB/L B/L B/L B/L B/L B/LBBBBRR
PPPL L LRR RR R
B
OP Gy
R
B/Y Sb
P/B
R/BLgB/RG/WBr/WB/L L Y
RB
B/LGy
R
O
O
R(BLACK) (BLACK)
B/W
4
1
3
2
5
67
8
10
9
1211
13
1415
16
17

IGNITION SYSTEM
8-3
1. Crankshaft position sensor
2. AC magneto
3. Rectifier/regulator
4. Joint connector
5. Condenser
7. Engine stop switch
9. ECU
10.Ignition coil
11.Spark plug

IGNITION SYSTEM
8-4
EAS1SL5323TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
Before troubleshooting, remove the following part(s):
1. Side cover (left/right)
2. Seat
3. Fuel tank
4. Air scoop (left/right)
5. Air filter case cover
1. Check the ignition system wire har-
ness connections.NG 
Reconnect.
OK 
2. Check the spark plug.
Refer to “CHECKING THE SPARK
PLUG” on page 3-35.NG 
Correct or replace the spark plug.
OK 
3. Check the ignition spark gap.
Refer to “CHECKING THE IGNI-
TION SPARK GAP” on page 8-41.OK 
The ignition system circuit is OK.
NG 
4. Check the ignition coil.
Refer to “CHECKING THE IGNI-
TION COIL” on page 8-41.NG 
Replace the ignition coil.
OK 
5. Check the engine stop switch.
Refer to “CHECKING THE
SWITCHES” on page 8-38.NG 
Replace the engine stop switch.
OK 
6. Check the crankshaft position sen-
sor.
Refer to “CHECKING THE CRANK-
SHAFT POSITION SENSOR” on
page 8-42.NG 
Replace the crankshaft position sensor.
OK 
7. Check the stator coil.
Refer to “CHECKING THE STA-
TOR COIL” on page 8-43.NG 
Replace the stator coil.
OK 

IGNITION SYSTEM
8-5
8. Check the ignition system wire har-
ness.
Refer to “CIRCUIT DIAGRAM” on
page 8-2.NG 
Repair or replace the wire harness.
OK 
Replace the ECU.

FUEL INJECTION SYSTEM
8-12
EAS1SL5328YAMAHA 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
90890-03231
Yamaha diagnostic tool (US)
90890-03234
Fault diagnosis mode Fault codes recorded on the ECU are read, and the con-
tents are displayed.
Function diagnostic mode Check the operation of the output value of each sensor
and actuator.
Inspection mode Determine whether each sensor or actuator is functioning
properly.
CO adjustment mode Adjust the concentration of CO admissions during idling.
Monitoring mode Displays a graph of sensor output values for actual oper-
ating conditions.
Logging mode Records and saves the sensor output value in actual driv-
ing conditions.
View log Displays the logging data.
ECU rewrite If 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
8-23
Fault code 33
SymptomIgnition coil: open or short circuit detected in the primary lead
of the ignition coil.
Fail-safe systemUnable to start engine
Unable to drive vehicle
Diagnostic code No.30
ActuationActuates the ignition coil five times at one-second intervals.
“WARNING” on the Yamaha diagnostic tool blinks five times when-
ever the ignition coil is actuated.
ProcedureCheck that a spark is generated five times.
• Connect an ignition checker.
Or-
derProbable cause of malfunc-
tion and checkMaintenance job Reinstatement method
1 Connection of ignition coil
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.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.
2 Connection 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.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.
3 Wire harness continuity. Open or short circuit  Re-
place the wire harness.
Between ignition coil coupler
and ECU coupler.
orange–orangeAfter 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.
4 Mounted condition of ignition
coil.
Check for looseness or
pinching.
Check the mounted condition
for correctness.Improperly mounted ignition
coil  Remount or replace
the ignition coil.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.
5 Defective ignition coil (test
the primary coils for continu-
ity).Check the primary resistance
of the ignition coil.
“CHECKING THE IGNITION
COIL” on page 8-41.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.

FUEL INJECTION SYSTEM
8-24
TIP
Disconnect the fuel pump coupler when this diagnostic tool is used. 6 Faulty ECU Execute the diagnostic mode.
(Code No. 30)
No spark  Replace the
ECU.
Fault code 39
Symptom Injector: open or short circuit detected.
Fail-safe systemUnable to start engine
Unable to drive vehicle
Diagnostic code No.36
ActuationActuates injector five times at one-second intervals.
“WARNING” on the Yamaha diagnostic tool blinks five times when
the injector is actuated.
ProcedureCheck that injector is actuated five times by listening for the oper-
ating sound.
Or-
derProbable cause of malfunc-
tion and checkMaintenance job Reinstatement method
1 Connection of injector cou-
pler.
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.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.
2 Defective injector. Check the injector.
“CHECKING THE FUEL IN-
JECTOR” on page 8-47.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.
3 Connection 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.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 33
SymptomIgnition coil: open or short circuit detected in the primary lead
of the ignition coil.