Yamaha YFZ450W Supplementary Service Manual Download

Page: 1 / 33

LIT-11616-20-13

5TG-28197-12

YFZ450W

YFZ450SEW

SUPPLEMENTARY

SERVICE MANUAL

Summary of Contents for YFZ450W

Page 1: ...LIT 11616 20 13 5TG 28197 12 YFZ450W YFZ450SEW SUPPLEMENTARY SERVICE MANUAL...

Page 2: ...ith 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 Ya...

Page 3: ...ions 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 s...

Page 4: ...arts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 4 is provided for removal and disassembly jobs 2 Num...

Page 5: ...E Wear limit clearance F Engine speed G Electrical data V A Symbols H to M in the exploded diagrams indicate the types of lubricants and lubrication points H Apply engine oil I Apply gear oil J Apply...

Page 6: ...ONTROL 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 ABSOR...

Page 7: ...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 4...

Page 8: ...ide 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 Cal...

Page 9: ...asten the clutch switch lead and handlebar switch lead with the plastic bands at the bends in the handlebar Fasten the front brake light switch lead and throttle switch lead with the plastic band at t...

Page 10: ...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 magneto coupler K Neu...

Page 11: ...and and then face the end of the band inward between the frame tubes 7 21 mm 0 28 0 83 in 57 77 mm 2 24 3 03 in Fasten the wire harness throttle position sensor lead and carburetor switch lead with th...

Page 12: ...attery 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 In...

Page 13: ...to lead through the guide on the fender stay 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 Insta...

Page 14: ...er do not pinch the clutch cable parking brake cable clutch switch lead and handlebar switch lead Fasten the cylinder head breather hose with the holder making sure that the catch of the holder is fac...

Page 15: ...for a long period of time the month maintenance intervals should be followed Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools data and technical skil...

Page 16: ...ace if necessary Check air pressure and balance and correct if nec essary 9 Wheel bearings Check for looseness or damage and replace if nec essary 10 Swingarm pivots Check operation and for excessive...

Page 17: ...Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every 2 years 23 Moving parts and cables Lubricate 24 Throttle lever hous ing and cable Check operation and cor...

Page 18: ...reload a Elevate the front wheels by placing a suit able stand under the frame b Loosen the locknut 1 c Turn the adjusting ring 2 in direction a or b NOTE _ Be sure to remove all dirt and mud from aro...

Page 19: ...75 90890 01443 T R Locknut 30 Nm 3 0 m kg 22 ft lb 2 Adjust rebound damping force a Turn the adjusting screw 1 in direction a or b NOTE Make sure that the position indicator marks c are aligned when t...

Page 20: ...are aligned when the shock absorber is set to the standard setting CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Direction a Compressi...

Page 21: ...s set to the standard setting CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Direction a Compression damping force is increased Directio...

Page 22: ...o remove all dirt and mud from around the locknut and adjusting ring before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION _ Never attempt to tur...

Page 23: ...b a 6 Adjust rebound damping force a Turn the adjusting screw 1 in direction a or b NOTE Make sure that the position indicator marks c are aligned when the shock absorber is set to the standard settin...

Page 24: ...gned when the shock absorber is set to the standard setting CAUTION _ Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Direction a Compression dam...

Page 25: ...igned when the shock absorber is set to the standard setting CAUTION _ Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged 9 Install seat Refer to SE...

Page 26: ...pipe Refer to ENGINE REMOVAL Manual No 5TG 28197 11 Rear brake light switch footrest right Refer to FRONT AND REAR BRAKES Manual No 5TG 28197 11 Clutch cover Refer to CLUTCH in chapter 4 Manual No 5TG...

Page 27: ...8 Oil pipe 1 1 9 Water pump breather hose 1 10 Right crankcase cover 1 11 Gasket 1 12 Oil nozzle 1 Refer to INSTALLING THE OIL NOZ ZLE 13 Impeller 1 14 Washer 1 15 Impeller shaft 1 16 Oil seal 1 17 B...

Page 28: ...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 NOTE Be sure to fit the projection on the oil...

Page 29: ...voir cap 1 2 Brake fluid reservoir diaphragm 1 3 Front brake light switch connector 2 Disconnect 4 Front brake light switch 1 5 Brake lever 1 6 Union bolt 1 Refer to INSTALLING THE FRONT BRAKE MASTER...

Page 30: ...re warning light K Neutral indicator light L Neutral switch M Diode 2 N Thermo switch 2 O Handlebar switch P Light switch Q Engine stop switch R Start switch S Headlight T Headlight relay 1 U Headligh...

Page 31: ......

Page 32: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A...

Page 33: ...B B L L Y Y O O B B L B Y B L B Y W B W R R B Sb R R R R R Y B Y B L B L B B B B B B Y B R B B Y Sb Y B L B L B W L R B W L Br Sb B W L Sb Sb Sb L B W L B O W B W BLACK BLACK O B BLACK GRAY GRAY R B...

Search results

Summary of Contents for YFZ450W

Reviews:

Related manuals for YFZ450W

Brands by name

Popular brands

Yamaha YFZ450W, Supplementary Service Manual

Search results

Summary of Contents for YFZ450W

Reviews:

Related manuals for YFZ450W

Brands by name

Popular brands