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Related Manuals for Yamaha YFZ450W
Summary of Contents for Yamaha YFZ450W
- Page 1 YFZ450W YFZ450SEW SUPPLEMENTARY SERVICE MANUAL LIT-11616-20-13 5TG-28197-12...
- Page 2 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)
- Page 3 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.
- Page 4 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.
- Page 5 EBS00006 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor 7 Chassis COOL CARB...
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Page 6: Table Of Contents
(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... -
Page 7: Specifications
GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS EBS01001 SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code 5D31, 5D34 EBS01002 ENGINE SPECIFICATIONS 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 ----... -
Page 8: Chassis Specifications
CHASSIS SPECIFICATIONS/ SPEC TIGHTENING TORQUES EBS01003 CHASSIS SPECIFICATIONS 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) -
Page 9: Cable Routing
SPEC CABLE ROUTING È Fasten the clutch switch lead and handlebar EBS00028 CABLE ROUTING switch lead with the plastic bands at the bends in 1 Parking brake cable the handlebar. É Fasten the front brake light switch lead and 2 Clutch cable 3 Clutch switch lead throttle switch lead with the plastic band at the 4 Handlebar switch lead... - Page 10 SPEC CABLE ROUTING 1 Indicator coupler B Negative battery lead M Throttle cable 2 Radiator fan motor coupler C Starter motor lead N Parking brake cable 3 Thermo switch 2 D Neutral switch lead O Clutch cable 4 Fuel tank breather hose E A.C.
- Page 11 SPEC CABLE ROUTING È Connect the neutral switch coupler and the A.C. Ê 7 ~ 21 mm (0.28 ~ 0.83 in) Ë 57 ~ 77 mm (2.24 ~ 3.03 in) magneto coupler, and then fasten the leads with Ì Fasten the wire harness, throttle position sensor the plastic band, making sure that they are routed under the frame and that they do not con- lead, and carburetor switch lead with the plastic...
- Page 12 SPEC CABLE ROUTING Ï Fasten the wire harness with the plastic band on Ñ Fasten the starter motor lead to the negative the positioning tape and then face the end of the battery lead at the mark on the battery lead with plastic band inward.
- Page 13 SPEC CABLE ROUTING Ô Fasten the neutral switch lead with the lead Ù Wrap the resistor lead around the frame as holder. shown in the illustration, and then fasten it with Õ Fasten the neutral switch lead with the clamp. the plastic band.
- Page 14 SPEC CABLE ROUTING Û When installing the fuel tank cover, do not pinch ß Fasten the cylinder head breather hose with the the front brake hose, throttle cable, front brake holder, making sure that the catch of the holder light switch lead, and throttle switch lead. is facing upward.
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Page 15: Periodic Checks And Adjustments
However, keep in mind that if the ATV isn’t used 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 skills. -
Page 16: General Maintenance And Lubrication Chart
GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY month Whichever CHECK OR MAINTE- ITEM comes first 1300 2500 2500 5000 NANCE JOB (mi) (200) (800) (1600) (1600) (3200) hours Every 20–40 hours (more often in wet or Air filter element •... - Page 17 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY month Whichever CHECK OR MAINTE- ITEM comes first 1300 2500 2500 5000 NANCE JOB (mi) (200) (800) (1600) (1600) (3200) hours • Check coolant level and ATV for coolant leakage, √ √ √ √...
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Page 18: Chassis
ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters) CHASSIS EBS00111 ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters) WARNING Always adjust the spring preload, rebound damping force and compression damping force of both front shock absorbers to the same setting. - Page 19 ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters) 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.
- Page 20 ADJUSTING THE FRONT SHOCK ABSORBERS (for models equipped with two compression damping adjusters) 3. Adjust: • compression damping force (fast compres- sion damping) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting bolt 1 in direction a or Compression damping Direction a force is increased.
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Page 21: Adjusting The Rear Shock Absorber (For Models Equipped With Two Compression Damping Adjusters)
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) 4. Adjust: • compression damping force (slow compres- sion damping) M MMM M MMM M MMM M MMM M MMM a. - Page 22 ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) 3. Disconnect the air filter case breather hose 1, and then remove the air filter case 2 with the air intake duct. 4. Adjust: • spring preload M MMM M MMM M MMM...
- Page 23 ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) Steering nut wrench P/N. YU-33975, 90890-01443 Locknut 44 Nm (4.4 m · kg, 32 ft · lb) NOTE: Always tighten the locknut against the adjust- ing ring, then torque it to specification. L LLL L LLL L LLL...
- Page 24 ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) 7. Adjust: • compression damping force (fast compres- sion damping) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting bolt 1 in direction a or Compression damping Direction a force is increased.
- Page 25 ADJUSTING THE REAR SHOCK ABSORBER (for models equipped with two compression damping adjusters) 8. Adjust: • compression damping force (slow compres- sion damping) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b.
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Page 26: Cooling System
COOL WATER PUMP EBS00134 COOLING SYSTEM WATER PUMP Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. Engine oil Drain. Coolant Drain. Exhaust pipe Refer to “ENGINE REMOVAL”. (Manual No.: 5TG-28197-11) Rear brake light switch/footrest (right) Refer to “FRONT AND REAR BRAKES”. - Page 27 COOL WATER PUMP Order Job/Part Q’ty Remarks Oil delivery pipe 1 Oil pipe 1 Water pump breather hose Right crankcase cover Gasket Oil nozzle Refer to “INSTALLING THE OIL NOZ- ZLE”. Impeller Washer Impeller shaft Oil seal Bearing Oil seal For installation, reverse the removal pro- cedure.
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Page 28: Checking The Oil Nozzle
COOL WATER PUMP 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 NOTE: Be sure to fit the projection on the oil nozzle into the groove in the right crankcase cover. -
Page 29: Chassis
CHAS FRONT AND REAR BRAKES EBS00407 CHASSIS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Brake fluid reservoir cap Brake fluid reservoir diaphragm Front brake light switch connector Disconnect. -
Page 30: Yfz450W/Yfz450Sew 2007 Wiring Diagram
YFZ450W/YFZ450SEW 2007 WIRING DIAGRAM 1 A.C. magneto COLOR CODE 2 Rectifier/regulator B ... Black 3 Main switch Br ..Brown 4 Battery G ... Green 5 Fuse L .... Blue 6 Starter relay O ... Orange 7 Starter motor R ... Red 8 Diode 1 Sb .. - Page 32 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
- Page 33 YFZ450W/YFZ450SEW 2007 WIRING DIAGRAM ( BLACK ) ( BLACK ) (BLACK) (BLACK) R Y/R (BLACK) Y/B B/Y (GRAY) ( BLACK ) (GRAY) Br/L Br/L Br/L ( BLACK ) Br/L ( GRAY ) ( GRAY ) L/B Br ( BLACK )