ECU YAMAHA YZ450F 2015 Owner's Manual

FRONT FORK
4-39
EAS1SL5167REMOVING THE FRONT FORK LEGS
1. Use a suitable stand to raise the front wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Record the adjusting screw setting position be-
fore loosening the adjuster and the base valve.
2. Loosen:
• Upper bracket pinch bolts
• Damper assembly
• Lower bracket pinch bolts
EWA13640
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
TIP
Before removing the front fork leg from the ve-
hicle, loosen the damper assembly “1” with the
cap bolt ring wrench “2”.
3. Remove:
• Front fork leg (s)
EAS1SL5168DISASSEMBLING THE FRONT FORK LEGS
1. Drain:
• Fork oil
2. Remove:
• Adjuster “1”
(from the inner tube)
TIP
• While compressing the inner tube “2”, set the
cap bolt ring wrench “4” between the inner
tube and locknut “3”.
• Hold the locknut and remove the adjuster.
ECA14180
NOTICE
Do not scratch the inner tube.
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flat-head screwdriver)
ECA14180
NOTICE
Do not scratch the inner tube.
4. Remove:
• Inner tube “1”
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a. Push in slowly “a” the inner tube just before
it bottoms out and then pull it back quickly
“b”.
b. Repeat this step until the inner tube can be
pulled out from the outer tube.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Cap bolt ring wrench
90890-01501
YM-01501
12
Cap bolt ring wrench
90890-01501
YM-01501
1
234
1
2

STEERING HEAD
4-50
EAS1SL5173REMOVING THE LOWER BRACKET
1. Use a suitable stand to raise the front wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Ring nut “1”
TIP
Remove the ring nut with the steering nut
wrench “2”.
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS1SL5174CHECKING THE STEERING HEAD
1. Wash with kerosene:
• Bearing
• Bearing races
2. Check:
• Bearing
• Bearing races
Damage/pitting  Replace.
3. Replace:
• Bearing
• Bearing races
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a. Remove the bearing race from the steering
head pipe with a long rod “1” and a hammer.
b. Remove the bearing race from the lower
bracket with a chisel “2” and a hammer.
c. Install a new bearing race.
ECA14270
NOTICE
If the bearing race is not installed properly,
the steering head pipe could be damaged.
TIP
Always replace the bearing and the bearing
race as a set.
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4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage  Replace.
EAS1SL5175INSTALLING THE STEERING HEAD
1. Install:
• Lower bearing “1”
TIP
Apply the lithium soap base grease on the dust
seal lip and bearing inner circumference. Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472

REAR SHOCK ABSORBER ASSEMBLY
4-56
EAS1SL5177HANDLING THE REAR SHOCK ABSORBEREWA13740
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make
sure that you understand the following in-
formation. The manufacturer cannot be held
responsible for property damage or person-
al injury that may result from improper han-
dling of the rear shock absorber.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion
due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
TIP
A break-in is required up to about 50 km of run-
ning.
EAS1SL5178DISPOSING OF A REAR SHOCK ABSORB-
ER
Before disposing the rear shock absorber, be
sure to extract the nitrogen gas from valve “1”.
EWA33DD052
WARNING
• Wear protective glasses to prevent your
eyes from damage due to possible gas or
metal chips scattered.
• To dispose of a damaged or a worn-out
rear shock absorber, take the unit to your
Yamaha dealer for this disposal proce-
dure.
EAS1SL5179REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Rear shock absorber assembly lower bolt
“1”
TIP
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:
• Rear shock absorber assembly upper bolt
• Rear shock absorber assembly
EAS1SL5180REMOVING THE BEARING
1. Remove:
• Stopper ring (upper bearing) “1”
TIP
Press in the bearing while pressing its outer
race and remove the stopper ring.
1
1

SWINGARM
4-61
EAS1SL5186REMOVING THE SWINGARM
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Measure:
• Swingarm side play
• Swingarm vertical movement
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a. Measure the tightening torque of the pivot
shaft nut.
b. Measure the swingarm side play “a” by mov-
ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, the bearings, and
the collars.
d. Check the swingarm vertical movement “b”
by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the spacers, the
bearings, and the collars.
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EAS1SL5187REMOVING THE BEARING
1. Remove:
• Bearing “1”
TIP
Remove the bearing by pressing its outer race.
EAS1SL5188CHECKING THE SWINGARM
1. Check:
• Swingarm
Bends/cracks/damage  Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends  Replace.
EWA13770
WARNING
Do not attempt to straighten a bent pivot
shaft.
3. Wash with kerosene:
• Pivot shaft
• Spacers
•Collars
• Bearing
4. Check:
• Oil seals
Damage  Replace.
• Bearing
• Spacers
Free play exists/unsmooth revolution/rust 
Replace bearing and bushing as a set. Pivot shaft nut
85 Nm (8.5 m·kgf, 61 ft·lbf)
Swingarm end free play limit (ra-
dial)
1.0 mm (0.04 in)
T R..

CHAIN DRIVE
4-64
EAS1SL5191REMOVING THE DRIVE CHAIN
1. Use a suitable stand to raise the rear wheel
off the ground.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Joint clip
• Drive chain joint “1”
• Drive chain “2”
EAS1SL5192CHECKING THE DRIVE CHAIN
1. Measure:
• 15-link section of the drive chain
Out of specification  Replace the drive
chain.
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a. Measure the length “a” between the inner
sides of the pins and the length “b” between
the outer sides of the pins on a 15-link sec-
tion of the drive chain as shown in the illus-
tration.
b. Calculate the length “c” of the 15-link section
of the drive chain using the following formu-
la.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2
TIP
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a differ-
ent location each time.
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2. Check:
•Drive chain
Stiffness  Clean, lubricate, or replace.
3. Clean:
•Drive chain
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a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
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15-link length limit
242.9 mm (9.56 in)

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

FUEL TANK
7-3
TIP
• Take care not to damage the installation sur-
faces of the fuel tank.
• Always use a new fuel pump gasket.
• Install the lip on the fuel pump gasket upward.
• Install the fuel pump as shown in the figure.
• Align the projection “a” on the fuel pump with
the slot “b” in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
EAS1SL5311INSTALLING THE FUEL TANK
1. Install:
• Fuel tank
2. Connect:
• Fuel hose
ECA33DD069
NOTICE
• Connect the fuel hose securely, and check
that the orientation of the installed fuel
hose holder is correct.
• Take care not to kink or pinch the fuel
hose.
TIP
• Insert the fuel hose into the fuel pipe securely
until you hear a “click”.
• Slide the fuel hose connector cover “1” at the
hose end in the direction of the arrow.
• Install the fuel hose connector holder “a”.
• Check that the fuel hose and the fuel pump
lead are routed through the guide on the cov-
er.3. Connect:
• Fuel pump coupler
4. Install:
• Air scoop (left/right)
• Seat
• Side cover (left/right)
Refer to “GENERAL CHASSIS” on page 4-
1.
EAS1SL5312CHECKING THE FUEL PRESSURE
1. Check:
• Fuel pressure
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a. Remove the side cover (left/right), the seat
and the air scoop (left/right).
Refer to “GENERAL CHASSIS” on page 4-
1.
b. Remove the fuel tank bolt and lift the fuel
tank.
c. Disconnect the fuel hose from the fuel
pump.
Refer to “REMOVING THE FUEL TANK” on
page 7-2.
EWA1DX1008
WARNING
Cover the fuel hose connection with a cloth
when disconnecting it. This is because re-
sidual pressure in the fuel hose could cause
fuel to spurt out when the hose is removed.
ECA1DX1025
NOTICE
Make sure that the fuel hose is disconnect-
ed by hand. Do not forcibly disconnect the
hose with tools.
a
b
4 1
2
6
53
1
a

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
8-3
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