Yamaha YFZ450W Manual

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
©2006 by Yamaha Motor Corporation, U.S.A.
First edition, April 2006
All rights reserved.
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
12
34
56
78
90
AB
CD
EFG
HIJ
KLM
NO
GEN
INFO SPEC
CHK
ADJ ENG
COOL CARB
CHAS
–+
ELEC
TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
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.
A
A
È
ÊË
Ì
2 3 4 5 61
6
É
7

–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
A
P
5
GG
GG
C
C
B
E
E
A
D-D
C-C
B-B
F-F E-E
F
F
D
D
G-G
B
7
2
56
7
890
A
B
C
D
E
F
É
Ê
Ì
Ë
Í
Î
Ï
Ð
Ò
Ñ
Ó
ÔÕ
Ö
Àß
×
Ø
G
E
DE
DQ
7
09
Û
Ý
Þ
I
H
Ù
Á
Ú
Ú
G
H
H
1
L
M
O
4
È
K
J
N
Ü
3