Yamaha YFZ450W Handbuch

LIT-11616-20-13 5TG-28197-12

YFZ450W

YFZ450SEW

SUPPLEMENTARY

SERVICE MANUAL

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

First edition, April 2006

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-20-13

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.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the vehicle operator, a bystander or a person checking or repairing the vehicle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the vehicle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.

2. Numbers 5are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8are given in addition

to the exploded diagram and the job instruction chart.

EBS00006

SYMBOLS

The following symbols are not relevant to

every vehicle.

Symbols 1to 9indicate the subject of each

chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Cooling system

6Carburetor

7Chassis

8Electrical

9Troubleshooting

Symbols 0to Gindicate the following

0Serviceable with engine mounted

AFilling fluid

BLubricant

CSpecial tool

DTightening torque

EWear limit, clearance

FEngine speed

GElectrical data (Ω, V, A)

Symbols Hto Min the exploded diagrams

indicate the types of lubricants and lubrication

points.

HApply engine oil

IApply gear oil

JApply molybdenum disulfide oil

KApply wheel bearing grease

LApply lithium-soap-based grease

MApply molybdenum disulfide grease

Symbols Nto Oin the exploded diagrams

indicate where to apply a locking agent Nand

when to install a new part O.

NApply the locking agent (LOCTITE®)

OReplace

EFG

HIJ

KLM

GEN

INFO SPEC

CHK

ADJ ENG

COOL CARB

CHAS

–+

ELEC

TRBL

SHTG

EGM

BLS M

New

CONTENTS

SPECIFICATIONS.............................................................................................. 1

GENERAL SPECIFICATIONS ..................................................................... 1

ENGINE SPECIFICATIONS......................................................................... 1

CHASSIS SPECIFICATIONS....................................................................... 2

TIGHTENING TORQUES............................................................................. 2

ENGINE TIGHTENING TORQUES ....................................................... 2

CABLE ROUTING ........................................................................................ 3

PERIODIC CHECKS AND ADJUSTMENTS...................................................... 9

INTRODUCTION .......................................................................................... 9

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM...................................................................................................... 9

GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 10

CHASSIS.................................................................................................... 12

ADJUSTING THE FRONT SHOCK ABSORBERS

(for models equipped with two compression damping adjusters) ....... 12

ADJUSTING THE REAR SHOCK ABSORBER

(for models equipped with two compression damping adjusters) ....... 15

COOLING SYSTEM.......................................................................................... 20

WATER PUMP ........................................................................................... 20

CHECKING THE OIL NOZZLE............................................................ 22

INSTALLING THE OIL NOZZLE.......................................................... 22

CHASSIS .......................................................................................................... 23

FRONT AND REAR BRAKES .................................................................... 23

FRONT BRAKE MASTER CYLINDER ................................................ 23

YFZ450W/YFZ450SEW 2007 WIRING DIAGRAM

–1 –

SPEC

EBS01001

SPECIFICATIONS

GENERAL SPECIFICATIONS

EBS01002

ENGINE SPECIFICATIONS

Item Standard

Model code 5D31, 5D34

Item Standard Limit

Clutch

Friction plate 1 (inside dia.: 119 mm)

Thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 2.8 mm

(0.110 in)

Quantity 7 ----

Friction plate 2 (inside dia.: 128 mm)

Thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 2.8 mm

(0.110 in)

Quantity 1 ----

Clutch plate

Thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) ----

Quantity 7 ----

Max. warpage ---- 0.2 mm

(0.0079 in)

Clutch spring

Free length 47.8 mm (1.88 in) 46.0 mm

(1.81 in)

Quantity 6 ----

Clutch housing thrust clearance 0.10 ~ 0.35 mm (0.0039 ~ 0.0138 in) ----

Clutch housing radial clearance 0.010 ~ 0.044 mm (0.0004 ~ 0.0017 in) ----

Clutch release method Inner push, cam push ----

Push rod 2 bending limit 0.1 mm (0.004 in) ----

GENERAL SPECIFICATIONS/

ENGINE SPECIFICATIONS

–2 –

SPEC

CHASSIS SPECIFICATIONS/

TIGHTENING TORQUES

EBS01003

CHASSIS SPECIFICATIONS

EBS01005

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Item Standard Limit

Rear disc brake

Type Single ----

Disc outside diameter ×thickness 200.0 ×4.0 mm (7.87 ×0.16 in) ----

Pad thickness inner 5.4 mm (0.21 in) 1.0 mm

(0.04 in)

Pad thickness outer 5.4 mm (0.21 in) 1.0 mm

(0.04 in)

Master cylinder inside diameter 12.7 mm (0.50 in) ----

Caliper cylinder inside diameter 25.4 mm (1.00 in) ----

Brake fluid type DOT 4 ----

Part to be tightened Part name Thread

size Q’ty Tightening torque Remarks

Nm m ·kg ft ·lb

Oil gallery bolt Bolt M6 1 7 0.7 5.1

–3 –

SPEC

CABLE ROUTING

EBS00028

CABLE ROUTING

1Parking brake cable

2Clutch cable

3Clutch switch lead

4Handlebar switch lead

5Front brake light switch lead

6Throttle switch lead

7Throttle cable

ÈFasten the clutch switch lead and handlebar

switch lead with the plastic bands at the bends in

the handlebar.

ÉFasten the front brake light switch lead and

throttle switch lead with the plastic band at the

bend in the handlebar.

ÊLess than 20 mm (0.79 in)

ËMake sure that there is no slack in the throttle

switch lead.

ÌFasten the throttle switch lead to the handlebar

with the plastic band.

ÊË

2 3 4 5 61

–4 –

SPEC

CABLE ROUTING

1Indicator coupler

2Radiator fan motor coupler

3Thermo switch 2

4Fuel tank breather hose

5Radiator fan motor lead

6Radiator fan breather hose

7Wire harness

8Fuel hose

9Throttle position sensor lead

0Carburetor switch lead

ACrankcase breather hose

BNegative battery lead

CStarter motor lead

DNeutral switch lead

EA.C. magneto lead

FOil tank breather hose

GResistor lead

HHeadlight relay 1

IHeadlight relay 2

JA.C. magneto coupler

KNeutral switch coupler

LFront brake hose

MThrottle cable

NParking brake cable

OClutch cable

PIndicator leads

QCylinder head breather hose

D-D

C-C

B-B

F-F E-E

G-G

890

ÔÕ

Àß

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