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2008 yamaha yz450f service manual free download. Yamaha YZ450F Online Motorcycle Service Manual 2006 – 2009



 

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The ranking of the best Yamaha bikes includes two-wheelers of different categories. These are the most bought motorcycles that can boast of reliability and excellent assembly. The Yamaha motorcycle rating looks like this:. These are the best motorcycles, which are chosen by thousands of motorists all over the world. These are spectacular, controllable bikes that will be the best choice.

Drive chain Engine stop switch Page Important Information 1. Remove all dirt, mud, dust, and 1. When ordering parts, you can foreign material before removal give the number to your Yamaha and disassembly. Keep away from fire. We recommend to use Yamaha 7. Check for continuity with a tester. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.

Cap bolt wrench This tool is used to loosen or tighten YM, the base valve. Cap bolt ring wrench This tool is used to loosen or tighten YM, Valve guide remover This tool is needed to remove and Intake 4. Continue push- ing the engine stop switch till the en- gine comes to a stop. Then, re- start the engine and check its op- eration within no more than 5 minutes after it is restarted. Operate the machine in the lower gears at moderate throttle open- ings for five to eight minutes.

Tank capacity 7. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book. Hot starter cable Pass the cylinder head breather Radiator hose 1 Carburetor breather hose hose on the outside of the radia- Cylinder head breather hose Carburetor overflow hose tor hose 1 and between the radi- Hose holder Insert the end of the fuel tank Install the connector cover so that it does not come in between the radiator hose 1 and radiator.

Pass the fuel hose between the hot starter cable and throttle po- sition sensor lead. Engine stop switch lead Fasten the hot starter cable and Clamp Sub-wire harness throttle cables onto the frame.

Throttle position sensor lead Ground lead Locate the clamp ends under Hump frame Pass the neutral switch lead on the inside of the engine bracket. Pass the neutral switch lead over the lower engine guard stay. Fasten the neutral switch lead and radiator breather hose to the frame.

Rear arm bracket Pass the cylinder head breather Cylinder head breather hose hose so that it does not contact Pass the throttle cables over the Install the brake hose so that its Install the brake hose so that its pipe portion directs as shown pipe portion directs as shown and lightly touches the projec- and lightly touches the projec Clutch cable Pass the brake hose in front of Engine stop switch lead the number plate. Cable guide Pass the throttle cables through Brake hose the cable guide.

Page Regular Inspection And Adjustments The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.

Scald- ing hot fluid and steam may be blown out under pressure, which could cause serious injury. LEVEL 1. Stand the machine on a level sur- face. Inspect: a. The field where these two coordinates intersect shows the new pad number to use.

Use the new pad number only as a guide when verifying the valve clear- ance adjustment. Install the new pads "3" and the valve lifters "4".

Connect the transparent hose "5" Install the pad pin plug "10". PADS" section. Loosen the pad pin "3". Remove the rear wheel "4" and Install the brake caliper "12" and brake caliper "5". Measure: 3. Adjust: 1 Nm 0. Check: et : e. Page 67 Footrest pivot avoid getting grease on the brake Throttle-to-handlebar contact discs.

Drive chain Tube guide cable winding por- tion Throttle cable end Clutch cable end Hot starter cable end Use Yamaha cable lube or equivalent on these areas. Disconnect the fuel hose. Seat Air scoop left and right Bolt fuel tank Fuel tank Left side cover Bolt silencer clamp Only loosening. Bolt [silencer front ] Bolt [silencer rear ] Collar Silencer Silencer clamp After that, retighten the nut ex- haust pipe 20 Nm 2.

Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open 2. Float pin Float Needle valve Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger Blow out all passages and changing the throttle position sen- jets with compressed air.

Recheck the float height. Install: 1. Install the diaphragm accelerator pump with its mark "a" facing the spring. Engine upper bracket left Spark plug Cylinder head breather hose Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Gasket Refer to removal section.

Remove: 0. Install the camshaft onto the cylin- 1. Inspect: der head. With the rod fully wound and the chain tensioner UP mark "a" fac- Do not turn the crankshaft during ing upward, install the gasket "1", the camshaft installation. Damage the timing chain tensioner "2", and or improper valve timing will re- the gasket "3", and tighten the bolt sult.

Remove the bolts. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section. Install the new valve guide using a be reinstalled in their original place. Measure: Valve seat width: the guide. While compressing the valve spring with a valve spring compressor "1" in- Free length valve stall the valve cotters.

Piston pin Refer to removal section. Piston Refer to removal section. Measure: c. Clutch cable Disconnect at engine side. Clutch cover Gasket Dowel pin Clutch spring Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft

   

 

Yamaha Service & Repair Manuals. DTC - Free Download PDF



   

Camshaft 2. Oil pressure check bolt 3. After connecting the neutral switch coupler, at- 1. Clutch cable tach the coupler cover. Throttle cable return R.

After connecting the AC magneto coupler, attach 3. Throttle cable pull the coupler cover. Launch control switch lead S. Insert the projection on the plastic locking tie into 1. Bracket the hole in the rear frame. Condenser T. Clamp the painted part on the fuel hose by the 3. Coolant temperature sensor plastic clamp. Make the lock on the plastic clamp 4.

Throttle cable 2. Clutch cable 3. Plastic band 4. Engine stop switch lead 5. Launch control switch lead 6. 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. Main harness 2. Radiator 3. Throttle position sensor lead 4. Joint coupler 5. Intake air temperature sensor lead 6.

Intake air pressure sensor lead 7. Frame 8. Fuel hose 9. High tension cord Spark plug cap Brake master cylinder 2. Brake hose holder 3. 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. The life of parts varies significantly according to the environment in which the machine runs e.

Replace Replace the piston, piston pin, piston pin clip, and piston ring all as a set. Before using this machine, check the following points.

Slide the clutch cable cover. Check: b. Wash: 7. After washing the element with air filter cleaner or kerosene, squeeze and dry it completely. Remove: 1. Therefore, do not add any chemical additives. Install the oil strainer. Oil strainer bolt 10 Nm 1. Record the measured reading if the clearance 4. Check: is incorrect. Before running, bleed the brake 1. Check: system. Replace: f. Do not reuse the drained brake fluid.

Tighten the bleed screw. Bleed screw 6 Nm 0. Loosen the bleed screw and push the brake caliper piston in. Check: 1. Securely support the vehicle so that there is Specified brake fluid no danger of it falling over. Stand the vehicle upright on a level surface. Tighten the locknut. Locknut 30 Nm 3. Tire air pressure measured on cold tires Front kPa 1. Use a suitable stand to raise the front wheel off the ground. Lubricate the pivoting points and metal-to- metal moving parts of the following parts.

Measure: 1. Page General Chassis This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles e. Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual. Use a suitable stand to raise the front wheel A tight spoke will emit a clear, ringing tone; a off the ground.

Clean the outside of the front wheel hub. Install: 3. NOTICE Before tightening the front wheel axle nut, push down hard on the handlebar s several times and check if the front fork rebounds smoothly.

Securely support the vehicle so that there is Radial wheel runout limit no danger of it falling over. Use new brake fluid for cleaning and lubricating. Install: 2. Therefore, always clean up any spilt brake fluid immediately.

Adjust if necessary. Union bolt Copper washers Brake hose Split pin Washer Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm plate Brake master cylinder reservoir diaphragm Rear brake master cylinder For installation, reverse the removal proce Clean: 1. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor Before removing the rear brake master cylin- brake performance.

Specified brake fluid 4. Pour brake fluid to the brake fluid reservoir 5. Check: up to the specified level.

Clutch cable Disconnect. Clutch lever holder Engine stop switch Launch control switch Brake master cylinder Throttle cable cap Throttle cable pull Disconnect. Throttle cable return Disconnect. If it does not, retighten the 7. Measure: 6. Install: Be careful not to dam- age the inner tube.

If torqued too much, it may cause Damper assembly the front fork to malfunction. Use a suitable stand to raise the front wheel If the bearing race is not installed properly, off the ground. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing. Remove: dure. Use a suitable stand to raise the rear wheel off the ground. Drive chain For installation, reverse the removal proce- dure.

Page Engine Removal This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles e. Realize you don't have the rights parts or knowledge to fix it.

Go and buy more parts to replace the ones you broke trying to fix the original problem. Create a shopping list and buy a few dollars worth of parts that you actually need. Fully indexed and searchable pdf manuals are portable and practicle. You can print out just the information you need to complete your job, then dispose of the printouts later when you are done. Page Control Functions The clutch lever "1" is located on the left handlebar; it disengages or en- gages the clutch.

Pull the clutch lever Your Yamaha engine has been de- to the handlebar to disengage the signed to use premium unleaded gas- clutch, and release the lever to en- oline with a pump octane number gage the clutch. When the engine starts running, 6. First, tighten the steering ring nut approximately 38 Nm 3. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.

Main axle Oil check bolt Drive axle Scavenging pump Oil level check window Oil feed pump Cylinder head breather hose Fit the accessory coupler into Hose holder the connector to fasten it to the Radiator hose 3 bracket. Cable holder Pass the clutch cable through Clamp the lower guide only.

Fasten the fuel hose and fuel Front engine bracket Face the buckle of the plastic pump lead with the plastic band, Fuel injector coupler above the cover. Atmospheric pressure sensor Throttle body Route the spark plug wire be- coupler Clamp Fasten the engine stop switch Engine stop switch lead lead to the handlebar. Hose guide Route the brake hose to the Main harness front of the number plate.

Page Regular Inspection And Adjustments If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.

The service life of the parts varies sub- stantially according to the environment in which the machine runs e. Inspect and clean Change gasket. Before using this machine, check the following points.

Do not remove the radiator cap "1", drain bolt and hoses when the engine and radiator are hot. Scald- Take care so that coolant does not ing hot fluid and steam may be splash on painted surfaces.

Apply the specified pressure. Attach: 1. Check: kPa 1. Apply: 4. Check: On the throttle cable end "a". Oil quantity: 2. Those place. Round off the last digit of the in- stalled pad number to the nearest increment. Tighten the bleed screw when the b. Tighten the locknut. Loosen the pad pin "2". Install the brake caliper "8" and c. Remove the brake caliper "3" tighten the pad pin "9". Locknut: from the front fork. Replace: h.

Install the brake pad "10" and pad 4. Remove: 6. Front B. There are marks 1. Loosen the locknut "1". Adjust: 1. Check: 1. Standard tire pressure: kPa 1. Loosen the steering ring nut one turn. Retighten the steering ring nut us- ing the steering nut wrench. Avoid over-tightening. Steering ring nut final tightening : 7 Nm 0.

Check the steering stem by turn- ing it lock to lock. All control cable Page 81 If a problem occurs that is not listed in this manual or if the problem cannot be corrected by the procedures provided in this manual, contact your Yamaha dealer. Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. Remove: 1. Crankshaft end accessing screw Refer to removal section.

Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Gasket Refer to removal section. Remove: Cam lobes length: 1. Camshaft-to-cap clear- ance: 0. With the rod fully wound and the chain tensioner UP mark "a" fac- ing upward, install the gasket "1", the timing chain tensioner "2", and the gasket "3", and tighten the bolt "4" to the specified torque.

Bolt timing chain ten- sioner : 10 Nm 1. Cylinder head Cylinder head gasket Timing chain guide intake side Coolant temperature sensor Oil check bolt Oil passage plug Tighten the cylinder head bolts to 30 Nm 3.

Tighten the bolts to the specified 1. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section. Intake: 1. Install: 1. Install the valve cotters by compress- ing the valve spring with the valve Free length valve spring compressor "1" Piston pin Refer to removal section. Piston Refer to removal section. Position: 2. Insert a ring into the cylinder and a. Measure the outside diameter push it approximately 40mm 1.

Clutch cable Disconnect at engine side. Clutch cover Gasket Clutch spring Pressure plate

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