YFZ450W YFZ450SEW SUPPLEMENTARY SERVICE MANUAL LIT-11616-20-13 5TG-28197-12
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFZ450W/YFZ450SEW. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. YFZ450S SERVICE MANUAL: LIT-11616-17-11 (5TG-28197-10) YFZ450V SUPPLEMENTARY SERVICE MANUAL: LIT-11616-19-32 (5TG-28197-11) YFZ450W/YFZ450SEW SUPPLEMENTARY SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A.
EBS00002 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe and unfit for use.
EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page.
1 EBS00006 2 GEN INFO SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter.
CONTENTS SPECIFICATIONS .............................................................................................. 1 GENERAL SPECIFICATIONS ..................................................................... 1 ENGINE SPECIFICATIONS......................................................................... 1 CHASSIS SPECIFICATIONS....................................................................... 2 TIGHTENING TORQUES.............................................................................
GENERAL SPECIFICATIONS/ ENGINE SPECIFICATIONS SPEC EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 5D31, 5D34 EBS01002 ENGINE SPECIFICATIONS Item Clutch Friction plate 1 (inside dia.: 119 mm) Thickness Quantity Friction plate 2 (inside dia.: 128 mm) Thickness Standard 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 7 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 1 Limit 2.8 mm (0.110 in) ---2.8 mm (0.110 in) ---- Quantity Clutch plate Thickness Quantity Max. warpage 1.5 ~ 1.7 mm (0.059 ~ 0.
CHASSIS SPECIFICATIONS/ TIGHTENING TORQUES SPEC EBS01003 CHASSIS SPECIFICATIONS Item Rear disc brake Type Disc outside diameter × thickness Pad thickness inner Standard Limit Single 200.0 × 4.0 mm (7.87 × 0.16 in) 5.4 mm (0.21 in) Pad thickness outer 5.4 mm (0.21 in) Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type 12.7 mm (0.50 in) 25.4 mm (1.00 in) DOT 4 ------1.0 mm (0.04 in) 1.0 mm (0.
CABLE ROUTING È Fasten the clutch switch lead and handlebar switch lead with the plastic bands at the bends in the handlebar. É Fasten the front brake light switch lead and throttle switch lead with the plastic band at the bend in the handlebar. Ê Less than 20 mm (0.79 in) Ë Make sure that there is no slack in the throttle switch lead. Ì Fasten the throttle switch lead to the handlebar with the plastic band.
CABLE ROUTING 1 Indicator coupler 2 Radiator fan motor coupler 3 Thermo switch 2 4 Fuel tank breather hose 5 Radiator fan motor lead 6 Radiator fan breather hose 7 Wire harness 8 Fuel hose 9 Throttle position sensor lead 0 Carburetor switch lead A Crankcase breather hose B Negative battery lead C Starter motor lead D Neutral switch lead E A.C. magneto lead F Oil tank breather hose G Resistor lead H Headlight relay 1 I Headlight relay 2 J A.C.
CABLE ROUTING Ê 7 ~ 21 mm (0.28 ~ 0.83 in) Ë 57 ~ 77 mm (2.24 ~ 3.03 in) Ì Fasten the wire harness, throttle position sensor lead, and carburetor switch lead with the plastic band. Make sure that there is no slack in the throttle position sensor lead and carburetor switch lead along the frame as shown. Í More than 15 mm (0.59 in) Î Install the cylinder head breather hose with the paint mark facing to the left. È Connect the neutral switch coupler and the A.C.
CABLE ROUTING Ñ Fasten the starter motor lead to the negative battery lead at the mark on the battery lead with the plastic band. Then, fasten the starter motor lead and negative battery lead to the frame with the plastic band and face the end of the band inward. Ò Install the crankcase breather hose with the paint mark facing to the left. Ó Route the neutral switch lead so that it does not contact the edges of the joint on the end of the oil pipe 2.
CABLE ROUTING Ù Wrap the resistor lead around the frame as shown in the illustration, and then fasten it with the plastic band. Face the end of the plastic band inward. Ú Install headlight relay 1 and headlight relay 2 to the inside of the frame, making sure to insert the tab on each relay completely into its rubber holder and to install the holders all the way onto the tabs on the stay. Ô Fasten the neutral switch lead with the lead holder. Õ Fasten the neutral switch lead with the clamp. Ö Fasten the A.
CABLE ROUTING ß Fasten the cylinder head breather hose with the holder, making sure that the catch of the holder is facing upward. À Fasten the A.C. magneto lead and neutral switch lead with the plastic band, making sure that the end of the band is on top of the frame, facing inward. Á Fasten the resistor lead with the holders. Û When installing the fuel tank cover, do not pinch the front brake hose, throttle cable, front brake light switch lead, and throttle switch lead.
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM CHK ADJ EBS00029 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced.
CHK ADJ GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL NO. ITEM CHECK OR MAINTENANCE JOB Whichever comes first 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 Every 20–40 hours (more often in wet or dusty areas) 1 Air filter element • Clean and replace if necessary. 2 * Clutch • Check operation and adjust if necessary. √ Front brake • Check operation and correct if necessary.
CHK ADJ GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL NO. 22 ITEM Cooling system CHECK OR MAINTENANCE JOB Whichever comes first EVERY month 1 3 6 6 12 km (mi) 320 (200) 1300 (800) 2500 (1600) 2500 (1600) 5000 (3200) hours 20 80 160 160 320 √ √ √ √ √ • Check coolant level and ATV for coolant leakage, and correct if necessary. • Replace coolant. Every 2 years 23 * Moving parts and cables • Lubricate.
ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters) CHK ADJ CHASSIS EBS00111 ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters) WARNING _ 1 2 a Always adjust the spring preload, rebound damping force and compression damping force of both front shock absorbers to the same setting. Uneven adjustment can result in poor handling and loss of stability. 1. Adjust: • spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters) CHK ADJ d. Tighten the locknut 1 with a steering nut wrench 3. NOTE: Set the torque wrench at a right angle to the steering nut wrench. Steering nut wrench P/N. YU-33975, 90890-01443 T. Locknut 30 Nm (3.0 m · kg, 22 ft · lb) R. NOTE: Always tighten the locknut against the adjusting ring, then torque it to specification. _ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters) CHK ADJ 3. Adjust: • compression damping force (fast compression damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt 1 in direction a or b. Direction a Compression damping force is increased. Direction b Compression damping force is decreased.
ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters)/ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) CHK ADJ 4. Adjust: • compression damping force (slow compression damping) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw 1 in direction a or b. Direction a Compression damping force is increased. Direction b Compression damping force is decreased.
ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) CHK ADJ 3. Disconnect the air filter case breather hose 1, and then remove the air filter case 2 with the air intake duct. 2 1 1 2 a b 4. Adjust: • spring preload ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Elevate the rear wheels by placing a suitable stand under the frame. b. Loosen the locknut 1. c. Turn the adjusting ring 2 in direction a or b. Direction a Spring preload is increased (suspension is harder).
ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) CHK ADJ Steering nut wrench P/N. YU-33975, 90890-01443 T. Locknut 44 Nm (4.4 m · kg, 32 ft · lb) R. NOTE: Always tighten the locknut against the adjusting ring, then torque it to specification. _ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b a 5. Install: • air filter case with air intake duct NOTE: Align the projection a on the carburetor with the slot b in the air intake duct. _ 6.
ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) CHK ADJ 7. Adjust: • compression damping force (fast compression damping) a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 b a. Turn the adjusting bolt 1 in direction a or b. 1 c Direction a Compression damping force is increased. Direction b Compression damping force is decreased.
ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) CHK ADJ 8. Adjust: • compression damping force (slow compression damping) a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1 b a. Turn the adjusting screw 1 in direction a or b. 1 c Direction a Compression damping force is increased. Direction b Compression damping force is decreased.
WATER PUMP COOL EBS00134 COOLING SYSTEM WATER PUMP Order Job/Part Removing the water pump Engine oil Coolant Exhaust pipe Q’ty Rear brake light switch/footrest (right) Clutch cover 1 2 3 4 5 6 Radiator outlet hose Water pump inlet pipe Water pump housing Oil filter element cover Oil filter element Parking brake holder 1 1 1 1 1 1 – 20 – Remarks Remove the parts in the order listed. Drain. Drain. Refer to “ENGINE REMOVAL”. (Manual No.: 5TG-28197-11) Refer to “FRONT AND REAR BRAKES”. (Manual No.
WATER PUMP Order 7 8 9 10 11 12 13 14 15 16 17 18 Job/Part Oil delivery pipe 1 Oil pipe 1 Water pump breather hose Right crankcase cover Gasket Oil nozzle Impeller Washer Impeller shaft Oil seal Bearing Oil seal COOL Q’ty Remarks 1 1 1 1 1 1 Refer to “INSTALLING THE OIL NOZZLE”. 1 1 1 1 1 1 For installation, reverse the removal procedure.
WATER PUMP COOL CHECKING THE OIL NOZZLE 1. Check: • oil nozzle Damage/wear → Replace the oil nozzle. • oil passage Obstruction → Blow out with compressed air. INSTALLING THE OIL NOZZLE 1. Install: • O-ring 1 • oil nozzle 2 2 NOTE: Be sure to fit the projection on the oil nozzle into the groove in the right crankcase cover.
FRONT AND REAR BRAKES CHAS EBS00407 CHASSIS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the front brake master cylinder Brake fluid Brake fluid reservoir cap Brake fluid reservoir diaphragm Front brake light switch connector Front brake light switch Brake lever Union bolt Copper washer Brake hose Brake master cylinder bracket Brake master cylinder Q’ty Remarks Remove the parts in the order listed. Drain. 1 1 2 1 1 1 2 1 1 1 Disconnect.
YFZ450W/YFZ450SEW 2007 WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Diode 1 9 Starting circuit cut-off relay 0 Clutch switch A C.D.I.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
YFZ450W/YFZ450SEW 2007 WIRING DIAGRAM W R R W W R (BLACK) (BLACK) Y/R W/B W Y 1 W/B Y/R W/B Y/R R 2 R R B/Y Y L R B/L R/B Sb O W B W/B (BLACK) (BLACK) R B W W/B B Y R Y/R R R O B R 4 15A (BLACK) B B 5 R R Y/B L/B W/B W R O C 6 L/B A R/B B/Y Y/B B/Y B B B B/Y Y/B Sb R/B 7 0 (BLACK) Y/B L Y B/L B/Y Sb 9 R/B R L Y B/L 3 Sb (GRAY) Y/B L/B Br Br/L (BLACK) Br/L B/Y Br O Br Br R/B L/B L/B X M R/B L L R/B Y R/B B B L/B Br Br R/W Y/W G Y P OFF
