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2006 YFZ450 Service Manual Supplement

1. lt d Y N gt 2 2174 gd D d i A KR A Y se NOS c 7 d gt E SA 7 7 We Vi P oM Ser 6 19 1 Wire harness 2 Air filter case breather hose 3 Cylinder head breather hose 4 Coolant reservoir breather hose 5 Coolant reservoir hose 6 Tail brake light breather hose 7 Tail brake light Tail brake light lead 9 Crankcase breather hose Carburetor drain hose 4 Carburetor air vent hose 5 S NI O mes NS S La CH 4 N N d 1 V as y f X D Ny 2 S NN XN 4 CABLE ROUTING SPEC y 2 Battery negative lead 3 Starter motor lead When installing the rear fender make sure that the rear fender does not overlap or pinch the cyl inder head breather hose coolant reservoir hose or wire harness Install the air filter case breather hose with the paint mark facing outward Install the cylinder head breather hose with the paint mark facing outward D Install the coolant reservoir breather hose with out twisting the hose Fasten the coolant reservoir hose and the cool ant reservoir breather hose with the holder mak ing sure that there is no slack in the hose Install the coolant reservoir breather hose as shown so that there is no slack
2. 31 ADJUSTING THE FRONT SHOCK 5 32 ADJUSTING THE REAR SHOCK ABSORBER 34 t E 38 ENGINE BEMOVA s 38 MUFFLERAND EXHAUST PIPE sintesi er a 38 INSTALLING THE PISTON DEE 39 COOLING SYSTEM usi nietos 40 RADIATOR MMC CU UR 40 WATER RUMP verrons CE 42 CHASSIS 44 FRONT AND REAR WHEEES sm 44 REARWAEE er 44 INSTALLING THE REAR WHEEL HUBS 45 REAR AXLE AND REAR AXLE 46 REMOVING THE REAR BRAKE 48 REMOVING THE REAR AAL Es piis inte prune satur Qua 48 INSTALLING THE DRIVEN SPROCKET eee 49 INSAEBING FEE BEAT EE 49 FHONE AND REAR BRAKES i etant M RUM 51 FRONT BRAKE PADS Mme qtu cee 51 REAR BRAKE RE 52 REAR BRAKE MASTER o3 INSTALLING THE REAR BRAKE MASTER CYLINDER 55 FRONT BRAKE CALIPER WEE 57 REAR BRAKE CALIPER 58 REMOVING THE REAR BRAKE 61 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERG 61 CHECKING THE FRONT AND REAR BRAKE CALIPERS 62 ASSEMBLING THE REAR BRAKE CALIPER esses 63 INSTALLING THE REAR
3. 55 FRONT AND 4 REAR BRAKES CHAS 36 Be careful that water does not enter the brake master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock Air bleed brake system 5 Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Manual No 5TG 28197 10 Check e brake fluid level 56 Brake fluid level is under the level line Add the recommended brake fluid to the proper level Hefer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 FRONT AND REAR BRAKES CHAS 56 EBS00423 FRONT BRAKE CALIPER Disassembling the front brake cali Remove the parts in the order listed pers The following procedure applies to both of the front brake calipers Brake pad retaining bolt Brake pad pad shim Brake pad spring Caliper bracket Caliper piston Refer to DISASSEMBLING THE Dust seal FRONT AND REAR BRAKE CALI Caliper piston seal PERS and ASSEMBLING THE FRONT BRAKE CALIPERS Manual No 5TG 28197 10 Bleed screw For assembly reverse the disassembly procedure FRONT AND REAR BRAKES CHAS 56 EBS00424 REAR BRAKE CALIPER 30 Nm 3 0 kg 22 ft Ib Removing the rear brake caliper Remove the parts in the order listed Brake fluid Drain Parking brake cable Disconnect Refer to REMOVING THE PARKING BRAKE CABLE Manual No 5TG 28197
4. V D y d AA X XN 4 OA lt lt SSO fion e If the chain slack cannot be adjusted replace the sprockets and drive chain as a set f Tighten the rear axle pinch bolts 1 Rear axle pinch bolt 25 21 Nm 2 1 kg 15 ft Ib NOTE nmm Tighten the rear axle pinch bolts 1 in the proper sequence as shown e he chain should be cleaned and lubricated after every use of the vehicle AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EBSOO 1 11 ADJUSTING THE FRONT SHOCK ABSORBERS A WARNING 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 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 8 or Spring preload is Direction increased suspension is harder Spring preload is Direction b decreased suspension is softer Adjusting length Standard 255 mm 10 04 in Minimum 246 5 mm 9 70 in Maximum 261 5 mm 10 30 in CHK 4o ADJUSTING THE FRONT SHOCK ABSORBERS ADJ NOTE AAA Be sure to remove all dirt and mud from around the locknut and adjusting ring before adjustment The length of the spring
5. End gap installed 0 20 0 30 mm 0 008 0 012 in 0 55 mm 0 022 in Side clearance 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 0047 in 2nd ring L A1 Dimensions B x T 1 00 x 3 35 mm 0 039 x 0 132 in End gap installed 0 35 0 50 mm 0 014 0 020 in 0 85 mm 0 034 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 0047 in ENGINE SPECIFICATIONS SPEC y Carburetor D mark Main jet Main air jet Jet needle Cutaway Pilot air jet Pilot outlet Pilot jet Bypass 1 Valve seat size Starter jet Float height Engine idle speed Intake vacuum Oil pump Oil pump type Inner rotor to outer rotor tip clear ance Outer rotor to oil pump housing clearance Bypass valve setting pressure 5TGC 30 155 01 0 NGNR 1 5 70 00 9 42 01 0 03 8 90 8 mm 0 31 in 1 750 1 850 r min More than 35 7 kPa 268 mmHg 10 5 inHg Trochoid Less than 0 12 mm 0 0047 in 0 09 0 17 mm 0 0035 0 0067 in 40 0 80 0 kPa 300 602 mmHg 11 8 23 7 inHg 0 20 mm 0 0079 in 0 24 mm 0 0094 in ENGINE SPECIFICATIONS SPEC ge Cylinder head tightening sequence EBSO1003 CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS SPEC Front suspension Shock absorber travel Fork spring free length Spring fitting length Spring rate K1 Spring rate K2 Optional spring Rear suspension Shock absorber travel Spring free length Spring fittin
6. Apply engine oil Apply gear oil 09 Apply molybdenum disulfide oil 2 Apply wheel bearing grease 02 Apply lithium soap based grease 3 Apply molybdenum disulfide grease Symbols to in the exploded diagrams indicate where to apply a locking agent 4 and when to install a new part 65 63 Apply the locking agent LOCTITE 5 Replace CONTENTS GENERAL INFORMATION ek teuer bru 1 Deh ee Eo ap DD PUE T E 1 SPECIFICATIONS ince ara mio dra a RU 2 GENERAL SP ECIFICA MONS s sia 2 ENGINE SPECIFIC AMONG ntt dim dex utn 4 CHASSIS SPECIFICA MONS 8 ELECTRICAL 2 9 TORGOUES 10 ENGINE TIGHTENING TORQUES eee 10 GHASSIS TIGHTENING TORQUES nee 10 CABLE ROU ICA EE 11 PERIODIC CHECKS AND 27 INTRODUCTION EE 27 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL 27 GENERAL MAINTENANCE AND LUBRICATION CHART 28 CHASO One ee ene nee Seer ae 29 ADJUSTING THE PARKING BRAKE eese 29 CHECKING THE BRAKE FLUID LEVEL 29 ADJUSTING THE DRIVE CHAIN
7. Check the main switch for continuity EBSO1041 Refer to CHECKING THE SWITCHES e Is the main switch OK iL YES 4 Replace the main switch Check the fuse for continuity Refer to CHECKING THE SWITCHES e Is the fuse OK YES 2 Replace the fuse 83 COOLING system ELEC 5 Circuit breaker fan motor EBS01086 4 Radiator f adiator fan motor Remove the circuit breaker from the wire Disconnect the radiator fan motor coupler harness from the wire harness NOTE e Connect the battery DC 12 V as shown The circuit breaker and its leads are attached Positive battery lead blue 1 to the wire harness with black tape at two Negative battery lead black 2 locations Connect the pocket tester Q x 1 to the circuit breaker e Does the radiator fan motor turn iL YES 1 NO Zero at 20 C 68 F The radiator fan motor is faulty and Circuit breaker resistance must be replaced YES NO Replace the circuit breaker 84 EBS01088 6 Thermo switch 1 Remove the thermo switch 1 from the radi ator Connect the pocket tester Q x 1 to the thermo switch 1 1 as shown e Immerse the thermo switch 1 in a con tainer filled with coolant e Place a thermometer 3 in the coolant Slowly heat the coolant then let it cool down to the specified temperature Check the thermo switch 1 for con
8. Ue 73 Nm 7 3 kg 53 ft Ib Job Part Remarks 7 Union bolt 8 Copper washer 9 Brake hose Disconnect 10 Brake master cylinder 11 Rear brake light switch 12 Right footrest 13 Brake pedal spring Refer to INSTALLING THE REAR BRAKE MAS TER CYLINDER For installation reverse the removal pro cedure 54 FRONT AND REAR BRAKES CHAS 56 EBS00419 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install copper washers brake hose 1 e union bolt 5 130 Nm 3 0 kg 2 2 ft Ib CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe 8 touches the projection as shown A WARNING Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 2 Install e brake fluid reservoir hose 1 NOTE Install the brake fluid reservoir hose with the white paint mark 8 facing up as shown 3 Fill e brake fluid reservoir Recommended brake fluid DOT 4 CAUTION Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately A WARNING Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance
9. YAMAHA YFZ450V SUPPLEMENTARY SERVICE MANUAL LIT 11616 19 32 5TG 28197 11 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the YFZ450V 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 BTG 28197 10 YFZ450V SUPPLEMENTARY SERVICE MANUAL 2005 by Yamaha Motor Corporation U S A First edition May 2005 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 19 32 500002 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 manu
10. ment Check coolant leakage Cooling system Repair if necessary Replace coolant every 24 months Check operation Lights and switches st headlight beams olo NOTE Recommended brake fluid DOT 4 Brake fluid replacement When disassembling the master cylinder or caliper cylinder replace the brake fluid Normally check the brake fluid level and add the fluid as required e On the inner parts of the master cylinder and caliper cylinder replace the oil seals every two years Replace the brake hoses every four years or if cracked or damaged A WARNING Indicates a potential hazard that could result in serious injury or death 28 ADJUSTING THE PARKING BRAKE CHK CHECKING THE BRAKE FLUID LEVEL CHASSIS ADJUSTING THE PARKING BRAKE 1 Check parking brake cable end length Out of specification Adjust Parking brake cable end length 47 51 mm 1 85 2 01 in 2 Adjust parking brake cable end length a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut in direction 8 or D until the specified brake cable end length is obtained Tighten the locknut 2 Slide the rubber cover to its original posi tion A WARNING After this adjustment is performed lift the rear wheels off the ground by placing a block under the engine and sp
11. 62 FRONT AND REAR BRAKES CHAS 56 EBS00432 ASSEMBLING THE REAR BRAKE CALIPER A WARNING All internal brake components should be cleaned and lubricated with new brake fluid only before installation Recommended brake fluid DOT 4 Replace the caliper piston seals and dust seals whenever the brake caliper is disas sembled 1 Install caliper piston seals 1 dust seals 2 2 Install brake caliper piston 1 3 Install e parking brake shaft 1 NOTE Screw the parking brake shaft all the way into the parking brake case making sure that the punch mark 8 in the shaft is between the embossed marks on the case 4 Install parking brake arm 1 NOTE L L Align the center 8 of the parking brake arm with the punch mark in the parking brake shaft as shown 63 2 FRONT AND REAR BRAKES CHAS EBS00436 INSTALLING THE REAR BRAKE CALIPER 1 Install brake caliper assembly 557277 brake caliper mounting bolts 1 E OE SC e brake hose 2 E L ge e copper washers union bolt CAUTION When installing the brake hose on the brake caliper make sure that the brake pipe touches the projection on the brake caliper WARNING Proper brake hose routing is essential to insure safe vehicle operation Refer to CABLE ROUTING in chapter 2 2 Fill e brake reservoir Recommended brake fluid DOT 4 CAUTI
12. Brake caliper mounting bolt Brake pad retaining bolt Brake pad pad shim Brake pad spring Refer to REPLACING THE FRONT BRAKE PADS Manual No 5TG 28197 10 For installation reverse the removal pro cedure 51 FRONT AND REAR BRAKES CHAS 56 EBS00401 REAR BRAKE PADS SR 4 Z SY DU 6 17 Nm 1 7 kg 12 ft Ib 43 Nm 4 3 m kg 31 ft Ib Removing the rear brake pads Remove the parts in the order listed Brake caliper mounting bolt Brake pad retaining bolt Brake pad Brake pad spring Refer to REPLACING THE REAR BRAKE PADS Manual No 5TG 28197 10 For installation reverse the removal pro cedure 52 FRONT AND REAR BRAKES CHAS 36 EBS00410 REAR BRAKE MASTER CYLINDER 30 Nm 3 0 m kg 22 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib SUE eg UM 73 Nm 7 3 kg 53 ft Ib Job Part Remarks Removing the rear brake master cyl Remove the parts in the order listed inder Right side cover right foot protector Refer to SEAT FENDERS AND FUEL TANK in chapter Manual No 5TG 28197 10 Brake fluid Drain Brake fluid reservoir hose cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose 53 FRONT AND REAR BRAKES CHAS 36 30 Nm 3 0 kg 22 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib SUE eg
13. Install the wire harness so that it does not hang from the rear fender SS a YR SASS v 9 Qe M X Ge XN 4 5S Q o A AS UN CABLE ROUTING SPEC ge Pass the carburetor drain hose and carburetor air vent hoses through the hose guide on the engine from the left side of the vehicle in the order listed Do not pinch the hoses 1 Route the negative battery lead to the outside of the carburetor drain hose Make sure that the cover is installed securely on the negative battery lead terminal 21 Houte the carburetor drain hose between the rear shock absorber and swingarm and then under the frame Houte the carburetor drain hose between the frame and connecting arm and let it hang freely under the vehicle Fasten the crankcase breather hose and starter motor lead with the holder in the order listed V e IN KU a CABLE ROUTING SPEC y Fasten the coolant reservoir hose on top of the cylinder head breather hose with the holder and then route the hoses along the frame making sure that they are not pinched or crushed O Fasten the tail brake light lead wire harness starter motor lead and negative battery lead with the holder in the order listed P Fasten the coolant reservoir hose tail brake light lead and tail brake light breather hose with the holder making sure that the catch of the holder
14. installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjusting ring beyond the maximum or minimum setting d Tighten the locknut 1 with a steering nut wrench 3 NOTE 7 7 7777 set the torque wrench at a right angle to the steering nut wrench Steering nut wrench P N YU 33975 90890 01443 Ko Locknut A 30 Nm 3 0 m kg 22 ft Ib NOTE _ Always tighten the locknut against the adjust ing ring then torque it to specification AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 2 Adjust rebound damping force 777 0 td a Turn the adjusting screw 1 in direction or Rebound damping force Rebound damping force Is decreased lh WER From the fully turned in position Standard 11 clicks out Minimum 22 clicks out Maximum 1 click out 33 ADJUSTING THE FRONT SHOCK ABSORBERS CHK ADJUSTING THE REAR SHOCK ABSORBER ADJ Q CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 3 Adjust compression damping force a Turn the adjusting screw 2 in direction or Compression damping Direction b Compression damping force is decreased From the fully turned in position S
15. per turn of the adjuster CAUTION Never attempt to turn the adjusting ring beyond the maximum or minimum setting d Tighten the locknut 1 with a steering nut wrench NOTE oet the torque wrench at a right angle to the steering nut wrench 35 4o ADJUSTING THE REAR SHOCK ABSORBER ADJ Vz Steering nut wrench P N YU 33975 90890 01443 Locknut 25 44 Nm 4 4 kg 32 ft Ib NOTE nmm Always tighten the locknut against the adjust ing ring then torque it to specification AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 5 Install e air filter case with air intake duct NOTE _____________________ Align the projection on the carburetor with the slot in the air intake duct 6 Adjust rebound damping force a Turn the adjusting screw 2 in direction or Rebound damping force Rebound damping force Minimum soft Adjusting screw fully turned out Standard Adjusting screw 1 1 4 turns out from the fully turned in position Maximum hard Adjusting screw fully turned in NOTE Make sure that the position indicator marks C 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 AA4AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 36 de ADJUSTING THE
16. 10 Union bolt Copper washer Refer to INSTALLING Brake hose Disconnect THE REAR BRAKE CALI Brake caliper mounting bolt PER Brake caliper assembly For installation reverse the removal pro cedure 58 FRONT AND REAR BRAKES CHAS 56 EBS00425 23 Nm 2 3 kg 17 ft Ib 16 Nm 1 6 m kg 11 ft Ib JobiPar Disassembling the rear brake cali Remove the parts in the order listed per Adjusting bolt Locknut Parking brake arm Refer to DISASSEMBLING THE Rubber boot FRONT AND REAR BRAKE CALI Parking brake shaft PERS and ASSEMBLING THE REAR BRAKE CALIPER Parking brake bracket bolt Parking brake case bracket Parking brake case Gasket Brake pad retaining bolt 6060006 ECO OVO 59 FRONT AND REAR BRAKES 23 Nm 2 3 kg 17 ft Ib 16 Nm 1 6 m kg 11 ft Ib 2 Brake pad spring Caliper bracket Brake caliper piston Refer to DISASSEMBLING THE Dust seal FRONT AND REAR BRAKE CALI Caliper piston seal PERS and ASSEMBLING THE REAR BRAKE CALIPER Brake pad 9 9 oq G6Oo Bleed screw S For assembly reverse the disassembly procedure 60 FRONT AND REAR BRAKES CHAS 36 REMOVING THE REAR BRAKE CALIPER 1 Remove rear brake caliper mounting bolts NOTES lll If the rear brake caliper can not be removed easily first remove the rear brake pads and then remove the rear brake cal
17. BRAKE CALIPER 64 STEERING ss d tutte n et eee teen nea 66 INSTALLING THE HANDLEBAR E 66 REAR SHOCK ABSORBER AND RELAY 67 INSTALLING THE RELAY ARM AND CONNECTING ARM 69 SWINGARM AND DRIVE 70 EBEECTRIGALE 5 5 een aude aA I eae UN 72 ELEGTIBRMICAE COMPONENTS eis 72 CHECKING THE SWITGHE EE 74 SYS TEM eec 76 CIRCUIT DIAGRAM EM 76 TROYBLESHOOTING E 77 CHECKING THE LIGHTING 5 80 COOGING SYO TEM 82 Sie INBI EE 82 TROUBLESHOOTING stet dee re MR URL ES 83 YFZ450V WIRING DIAGRAM SPECIAL TOOLS ES 976 GENERAL INFORMATION 500021 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune up and assembly Use only the appropriate special tools this will help prevent damage caused by the use of inappropriate tools or improvised techniques Special tools may differ by shape and part number from country to country In such a case two types are provided When placing an order refer to the list provided below to avoid any mistakes For US and CDN P N YM YU YS YK ACC Except for US and CDN P N 90890 Rear axle nut wrench 46 mm 90890 01498 YM 37134 This tool is used to loosen or tighten the rear axle nut GENE
18. Gasket Refer to SEAT FENDERS AND FUEL TANK in chapter 3 Manual No 5TG 28197 10 For installation reverse the removal pro cedure 38 ENGINE REMOVAL ENG EBS00252 INSTALLING THE PISTON 1 Install piston rings onto the piston NOTE Be sure to install the piston rings so that the manufacturers marks or numbers are located on the upper side of the rings e Lubricate the piston and piston rings liberally with engine oil 2 Position e top ring e 2nd ring oil ring Offset the piston ring end gaps as shown Top ring end D 2nd ring end Oil ring end upper Oil ring Oil ring end lower 3 Install e piston 1 e piston pin 2 piston pin clips 3 NOTE e Apply engine oil onto the piston pin piston rings and piston Be sure that the punch mark on the piston points to the exhaust side of the engine Before installing the piston pin clips cover the crankcase with a clean rag to prevent the piston pin clips from falling into the crank case e When installing a piston pin clip make sure that the clip ends are 3 mm 0 12 in or more from the cutout in the piston 39 RADIATOR coo COOLING SYSTEM EBS00125 RADIATOR 9 Nm 0 9 kg 6 5 ft Ib 28 Nm 2 8 kg 20 ft Ib 7 Nm 0 7 kg 5 1 ft Ib 28 Nm 2 8 m kg 20 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Removing the radiat
19. Rectifier regulator 3 Main switch 4 Battery 5 Fuse 69 Light switch 09 Headlight Headlight relay 1 2 Headlight relay 2 G2 Resistor 83 Tail brake light LIGHTING SYSTEM ELEC TROUBLESHOOTING A f the followina fail to liaht head e Check the condition of the battery fie ew M NN head Refer to CHECKING AND CHARGING IE THE BATTERY in chapter 3 Check Manual No 5TG 28197 10 1 fuse Minimum open circuit voltage 2 battery ri 12 8 V or more at 20 C 68 F 3 main switch 4 light switch 5 lighting coil resistance 6 headlight relay 1 iL WES 1 ES 7 headlight relay 2 8 resistor resistance e Clean the battery 9 wiring connections terminals of the entire lighting system e Recharge or NOTE replace the battery Before troubleshooting remove the following EAS00783 part s 1 seat 3 Main switch 2 fuel tank cover e Check the main switch for continuity 3 side covers left and right Refer to CHECKING THE SWITCHES 4 front fender Is the main switch OK Troubleshoot with the following special tool s YES 1 NO Replace the main switch 4 Light switch Check the fuse for continuity Check the light switch for continuity Refer to CHECKING THE SWITCHES Refer to CHECKING THE SWITCHES Is the fuse OK Is the light switch OK YES A YES Replace the fuse Re
20. in this order Fasten the radiator fan breather hose with the holder on the radiator grill Install the brake hose cover so that the slits in the cover fit over the brake hose grommet Install the brake hose cover so that the bend in the cover aligns with the bend in the upper front arm e E EA H 14 CABLE ROUTING CABLE ROUTING SPEC y CD Indicator coupler 2 Negative battery lead 3 Throttle cable 2 Radiator fan motor coupler 3 Starter motor lead 4 Parking brake cable 3 Thermo switch 2 Neutral switch lead Clutch cable 4 Fuel tank breather hose 5 A C magneto lead 06 Indicator leads 5 Radiator fan motor lead Oil tank breather hose 07 Cylinder head breather hose 6 Radiator fan breather hose 7 Resistor lead Wire harness Headlight relay 1 Fuel hose Headlight relay 2 9 Throttle position sensor lead 09 A C magneto coupler Carburetor switch lead Neutral switch coupler 4 Crankcase breather hose 62 Front brake hose M 1 b et H NI A De A 2 6 UR Wi Nu 15 CABLE ROUTING SPEC ge Route the neutral switch lead A C magneto Fasten the wire harness thermo switch 2 lead lead and radiator fan motor lead under the A C magneto lead resistor lead neutral switch frame Connect the neutral switch lead and the lead and radiator fan motor lead
21. is facing inward 22 CABLE ROUTING SPEC ge CD Brake fluid reservoir hose Fasten the coolant reservoir hose with a clamp 2 Rear brake light switch lead so that it is not pinched 3 Throttle cable 4 Clutch cable Route the thermo switch 1 lead under the frame Fasten the thermo switch 1 lead with a plastic 5 Coolant reservoir hose band between the diode 1 and the diode 2 and 6 Oil tank breather hose then face the end of the band inward Thermo switch 1 lead D Fasten the resistor lead with a plastic band and Resistor lead then face the end of the band inward 9 Parking brake cable Pass the parking brake cable through the cable guide di gt 2 5 el KE M S X Lm Tr E D OI X 7 CR SE N JA j Ss 2 TZ RM OOD 4 E L4 e ed ir p 857 7 H PZ 2 P I 5 PAW 2 23 CABLE ROUTING SPEC y CD Rear brake hose Pass the brake fluid reservoir hose through the 2 Parking brake cable guide 3 Brake fluid reservoir hose Route the rear brake light switch lead to the 2 Rear brake light switch inside of the brake fluid reservoir hose so that it 5 Rear brake light switch lead will not contact the rider s leg Pass the brake fluid reservoir hose and rear brake lig
22. with the plastic A C magneto lead and then fasten the leads band and then face the end of the band inward with the plastic band making sure that they are between the frame tubes routed under the frame and that they do not con Route the fuel tank breather hose behind the tact headlight relay 2 steering stem D 7 21 mm 0 28 0 83 in 50 70 mm 1 97 2 76 in N A Ll d Li N ei 2 1 i 2 lt WSS d 2 7 gt We ou CH 2 A d BIR 9 e C Y AN X 7 215 lt N d d i i KR A Ei be Y I 7 NOS LET Ci 7 i X B i 220 4 7 7 We Vi a a On Ser 6 16 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 More than 15 mm 0 59 in Install the cylinder head breather hose with the paint mark facing to the left 1 Fasten the wire harness with the plastic band on the positioning tape and then face the end of the plastic band inward CABLE ROUTING SPEC y Fasten the negative battery lead and starter motor lead with the plastic band and then face the end of the plastic band inward Fasten the starter motor lead to the n
23. 5 ft Ib Loosen the rear axle nuts completely d Retighten the rear axle nuts to specification Rear axle nut 25 200 Nm 20 0 m kg 145 ft Ib NOTE Do not loosen the axle nuts after torquing them If an axle nut slot is not aligned with the cotter pin hole on either side of the axle fur ther tighten the axle nut until a slot is aligned with the hole 45 REAR AXLE AND REAR AXLE HUB CHAS 36 REAR AXLE AND REAR AXLE HUB 21 Nm 2 1 kg 15 ft Ib x a N 72 Nm 7 2 m kg 52 ft Ib 7 240 Nm 24 0 kg 175 ft Ib Job Part Hemarks Removing the rear axle and rear axle Remove the parts in the order listed hub Hear wheels rear wheel hubs Refer to FRONT AND REAR WHEELS Manual No 5TG 28197 10 Rear axle ring nut set bolt Rear axle ring nut Conical spring washer Rear axle pinch bolt Brake caliper NOTE Do not apply the brake pedal and do not use the parking brake when the brake caliper is off of the brake disc as the brake pads will be force shut Refer to REMOVING THE REAR AXLE and INSTALLING THE REAR AXLE 46 REAR AXLE AND REAR AXLE HUB CHAS 36 21 Nm 2 1 kg 15 ft Ib x a N 72 Nm 7 2 m kg 52 ft Ib 7 240 Nm 24 0 kg 175 ft Ib Job Part Brake disc brake disc bracket Rear axle Circlip Driven sprocket sprocket bracke
24. 70 CHECKING THE LIGHTING SYSTEM 1 The headlights fail to come on 1 Headlight bulbs and sockets e Check the headlight bulbs and sockets for e Set the main switch to ON continuity e Start the engine Refer to CHECKING THE BULBS AND e Set the light switch to LO or HP BULB SOCKETS e Measure the voltage AC 12 V of yellow Manual No 5TG 28197 10 or green on the headlight coupler Are the headlight bulbs and sockets OK wire harness side 5 the voltage within specification YES NO YES J NO Replace the head light bulb socket or This circuit is OK Replace the rectifier regulator both 80 LIGHTING System ELEC 2 Voltage 1 Tail brake light Connect the pocket tester DC 20 V to the Disconnect the tail brake light coupler tail brake light coupler as shown Connect the battery 12 V to the tail brake Tail brake light coupler wire harness side d rue shown Tail brake light en the jumper leads are connected to Positive tester probe gt blue the terminals the tail brake light should Negative tester probe gt black illuminate 2 The taillight fails to come on e Set the main switch to ON e Start the engine e Set the light switch to LO or Is the tail brake light OK Measure the voltage DC 12 V of blue 1 on the tail brake light coupler wire har iL YES 4 ES ness side 5 the voltage within s
25. ON Brake fluid may damage painted surfaces or plastic parts Always clean up spilled brake fluid immediately WARNING e Use only the designated quality brake fluid other brake fluids may deteriorate the rubber seals causing leakage and poor brake performance Refill with the same type of brake fluid mixing brake fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the brake fluid and may result in vapor lock 64 FRONT AND REAR BRAKES CHAS 56 3 Air bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter Manual No 5TG 28197 10 4 Check brake fluid level Brake fluid level is below the LOWER level line Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 5 Adjust parking brake cable end length a Loosen the locknut 1 and adjusting bolt 2 b Slide back the rubber cover 3 Loosen the locknut 4 d Turn the adjusting nut in direction or C until the specified brake cable end length 8 is obtained Parking brake cable end length 47 51 mm 1 85 2 01 in e Tighten the locknut f Slowly turn the adjusting bolt 2 clockwise until resista
26. RAL SPECIFICATIONS SPEC y SPECIFICATIONS GENERAL SPECIFICATIONS Model code 5TGC Dimensions Overall length 1 840 mm 72 4 in Overall width 1 170 mm 46 1 in Overall height 1 090 mm 42 9 in Seat height 810 mm 31 9 in Wheelbase 1 280 mm 50 4 in Minimum ground clearance 255 mm 10 04 in Minimum turning radius 3 500 mm 137 8 in Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Forward inclined single cylinder Displacement 449 cm 27 40 cu in Bore x stroke 95 0 x 63 4 mm 3 74 x 2 50 in Compression ratio 11 2 1 otarting system Electric starter Carburetor Type quantity FCR39H x 1 Manufacturer KEIHIN Tire Type Tubeless oize AT21 x 7R 10 AT20 x 10 9 Manufacturer DUNLOP DUNLOP Type KT341 Radial KT355A Radial EBS01001 Tire pressure cold tire Maximum load 100 kg 220 Ib Off road riding front 27 5 kPa 0 28 kg cm 4 0 psi rear 30 kPa 0 30 kg cm 4 4 psi Load is the total weight of cargo rider and accessories GENERAL SPECIFICATIONS SPEC y Wheel travel Front wheel travel 230 mm 9 06 in Rear wheel travel Bulb voltage wattage quantity 270 mm 10 63 in Headlight 12 V 30 W 30 W x2 Tail brake light 12 V 0 5 W 3 9 W x 1 Indicator and warning lights Neutral 12V 1 7W x 1 Coolant temperature 12V 1 7W x 1 EBS01002 ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS SPEC y Camshaft Drive method Camshaft cap inside diameter Camshaft journal diameter Camshaft
27. REAR SHOCK ABSORBER ADJ 7 Adjust compression damping force a Turn the adjusting screw 2 in direction or Compression damping Direction air force is increased Compression damping force is decreased Direction b Minimum soft Adjusting screw fully turned out Standard Adjusting screw 1 3 4 turns out from the fully turned in position Maximum hard Adjusting screw fully turned in NOTE L _ Make sure that the position indicator marks C 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 AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 8 Install seat Refer to SEAT FENDERS AND FUEL TANK Manual No 5TG 28197 10 37 ENGINE REMOVAL e EBS00198 ENGINE ENGINE REMOVAL MUFFLER AND EXHAUST PIPE 34 Nm 3 4 kg 24 ft Ib 14 Nm 1 4 kg 10 ft Ib 7 Nm 0 7 kg 5 1 ft Ib Removing the muffler and exhaust Remove the parts in the order listed pipe Seat fuel tank cover side covers left and right Fuel tank Right foot protector engine skid plate Clamp Loosen Muffler Refer to INSTALLING Muffler protector THE EXHAUST PIPE Gasket AND MUFFLER Man Exhaust pipe ual No 5TG 28197 10 Exhaust pipe protector
28. al 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 AN The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING 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 CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle NOTE A NOTE provides key information to make procedures easier or clearer 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 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 4 is provided for removal and disassembly jobs 2 N
29. d and spline e Attach a suitable socket 2 on the axle end and tap it with a soft hammer then pull out the rear axle to the left 8 Remove circlip driven sprocket bracket INSTALLING THE DRIVEN SPROCKET 1 Install driven sprocket NOTE 5L Make sure that the blunt edged corner 8 of the driven sprocket is facing outward EBS00397 INSTALLING THE REAR AXLE 1 Install conical spring washer 1 NOTE AAA Install the conical spring washer with the con vex side of the washer facing outward as shown 49 REAR AXLE AND REAR AXLE HUB CHAS 56 2 Tighten rear axle ring nut 1 a Tighten the rear axle ring nut with rear axle nut wrench 46 mm 2 to specification while holding the rear axle Rear axle nut wrench 46 mm 2 V P N YM 37134 90890 01498 Rear axle ring nut 240 Nm 24 0 m kg 175 ft Ib LOCTITE Rear axle ring nut set bolt 7 Nm 0 7 kg 5 1 ft Ib LOCTITE AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 50 FRONT AND REAR BRAKES CHAS 56 EBS00400 FRONT AND REAR BRAKES FRONT BRAKE PADS 17 Nm 1 7 m kg 12 ft Ib 28 Nm 2 8 kg 20 ft Ib Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers Front wheel Refer to FRONT AND REAR WHEELS Manual No 5TG 28197 10
30. d swingarm Footrest and frame Front brake pad retaining bolt Rear brake pad retaining bolt NOTE W 1 Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel hub surfaces that contact the rear axle washers 2 Tighten the rear axle nuts 200 Nm 20 0 m kg 145 ft Ib Loosen the rear axle nuts completely 4 Retighten the rear axle nuts 200 Nm 20 0 m kg 145 ft Ib Do not loosen the axle nuts after tightening them If an axle nut slot is not aligned with the cotter pin hole on either side of the axle further tighten the axle nut until a slot is aligned with the hole 10 CABLE ROUTING SPEC y GEN Fasten the clutch switch lead and handlebar CABLE ROUTING switch lead with the plastic bands at the bends in D Parking brake cable the handlebar 2 Clutch cable Fasten the front brake light switch lead and 8 Clutch switch lead throttle switch lead with the plastic band at the 4 Handlebar switch lead bend in the handlebar 8 Front brake light switch lead Less than 10 mm 0 39 in 6 Throttle switch lead D Make sure that there is no slack in the throttle 7 Front brake hose switch lead Throttle cable Fasten the throttle switch lead to the handlebar with the plastic band 11 D Throttle cable 2 Front brake hose 3 Front brake light switch lead 4 Throttle switch lead 5 Clutch cable 6 Parking brake cable Clutch switch lead Handl
31. ebar switch lead 9 Radiator fan breather hose Thermo switch 2 lead 17 Headlight coupler left ANNAN H UM Pa E i CABLE ROUTING SPEC y 2 C D I unit leads 3 Rectifier regulator coupler Front brake pipe 5 Rectifier regulator Diode 1 7 Headlight coupler right Diode 2 Thermo switch 1 lead 0 Main switch coupler 0 C D I unit 12 Pass the throttle cable through the cable guide Pass the throttle cable leads front brake light switch throttle switch clutch switch and handle bar switch parking brake cable and clutch cable through the cable guide in the order listed Pass the throttle cable through the steering stem cable guide D 50 70 mm 1 97 2 76 in e E EA 13 CABLE ROUTING SPEC y Fasten the front brake light switch lead throttle switch lead clutch switch lead and handlebar switch lead with the plastic band and then place the end of the band under the fuel tank cover Pass the radiator fan breather hose through the hose guide Slide the rubber cover over the couplers front brake light switch throttle switch clutch switch and handlebar switch and fasten the center of the cover with the plastic band Fasten the radiator fan breather hose clutch cable and parking brake cable with the clamp 1 Pass the clutch cable and parking brake cable through the cable guide
32. egative 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 Install the crankcase breather hose with the paint mark facing to the left N A NM j ni N lt 1 4 2 lt WSS d gt 7 d GEES A SC CH 2 A d OLR lt d c OY Y pu N W f 2174 gd i UM A d SS ue NOS c 7 d gt E v A 7 7 We Vi a a oM Ser 6 417 Route the neutral switch lead so that it does not contact the edges of the joint on the end of the oil pipe 2 Fasten the neutral switch lead with the lead holder O Fasten the neutral switch lead with the clamp P Fasten the A C magneto lead with the lead holder Fasten the neutral switch lead and A C mag neto lead with the plastic band Face the end of the plastic band inward on top of the frame CABLE ROUTING SPEC y R Pass the neutral switch lead and A C magneto lead through the guide on the fender stay S 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 Install headlight relay 1 and headlight relay 2 to the inside of the frame making sure to
33. g length Spring rate K1 Stroke K1 Optional spring Front disc brake Type Disc outside diameter x thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Rear disc brake Type Disc outside diameter x thickness Pad thickness inner Pad thickness outer Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type Brake lever and brake pedal Brake pedal position Parking brake cable end length Clutch lever free play lever end Throttle lever free play Speed limiter length Shift pedal height 110 mm 4 33 in 265 mm 10 43 in 255 mm 10 04 in 15 0 N mm 1 53 kg mm 86 Ib in 35 0 N mm 3 57 kg mm 200 Ib in NO 126 4 96 in 272 mm 10 71 in 257 mm 10 12 in 36 0 N mm 3 67 kg mm 206 Ib in 126 mm 0 4 96 in NO Dual 161 0 x 3 5 mm 6 34 x 0 14 in 4 3 0 17 1 0 0 04 in 1 0 0 04 in 12 7 mm 0 50 in 25 4 mm 1 00 in DOT 4 4 3 mm 0 17 in Single 200 0 x 3 6 mm 7 87 x 0 14 in 5 4 mm 0 21 in 5 4 mm 0 21 in 12 7 mm 0 50 in 25 4 mm 1 00 in DOT 4 11 7 mm 0 46 in SS 47 51 mm 1 85 2 01 in iuo 8 13 mm 0 31 0 51 in Suse 2 4mm 0 08 0 16 in E Less than 12 mm 0 47 in 25 0 98 ELECTRICAL SPECIFICATIONS SPEC y EBS01004 ELECTRICAL SPECIFICATIONS Headlight relay Headlight
34. ght switch 09 Headlight relay 1 2 Headlight relay 2 02 Radiator fan 63 Circuit breaker fan motor GA 4 Rectifier regulator 65 C D I unit G Resistor 07 Headlight Diode 2 9 Diode 1 Thermo switch 1 7a CHECKING THE SWITCHES ELEC Check each switch for damage or wear proper connections and also for continuity between the ter minals Refer to CHECKING SWITCH CONTINUITY Manual No 5TG 28197 10 CHECKING THE SWITCHES EBS01029 Damage wear Repair or replace Improperly connected Properly connect Incorrect continuity reading Replace the switch 74 CD Light switch 2 Engine stop switch 3 Start switch 4 Front brake light switch 5 Throttle switch 6 Main switch 7 Clutch switch Carburetor switch 9 Fuse Rear brake light switch 17 Neutral switch CHECKING THE SWITCHES ELEC 75 EBS00518 LIGHTING SYSTEM CIRCUIT DIAGRAM iia the a ee ln ee c Gs e lt DC e d op g l e m agp were otra NC SMS ERE gt 2 11 Beli 1 Se 1 tr e EM prs LIGHTING SYSTEM Br L 76 CD A C magneto 2
35. haust system e Tighten if necessary Replace gasket if necessary poland Q O O Spark arrester Clean 27 CHK GENERAL MAINTENANCE AND LUBRICATION CHART ADJ Q GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL EVERY 320 200 km 1300 2500 2500 5000 mi 800 1600 1600 3200 Clean Every 20 40 hours Air filter element e Replace if necessary more often in wet or dusty areas Clutch Check operation e Adjust if necessary Front brake e Check free play operation fluid leakage See NOTE Correct if necessary Rear brake Check operation fluid leakage See NOTE Correct if necessary Check balance damage runout Replace if necessary SE Check bearing assemblies for looseness damage Wheel bearings Replace if damaged Lubricate every 6 months with lithium soap based EE Whichever comes first ROUTINE Rear arm pivots grease Upper and lower arm pivot and steering shaft Lubricate every 6 months with lithium soap based grease Check and adjust slack alignment clean lube meow Fittings and fasten Check all chassis fittings and fasteners ers Correct if necessary Front and rear sus Check operation pension Correct if necessary Check operation x Repair if damaged Steering system s Ol Sci Adjust if necessary Replace Warm engine before draining Engine oil filter ele Replace
36. ht switch lead through the hose holder D Install the brake hose holder so that the projec tion on its end aligns with the line on the swing arm as shown the illustration 24 17 Starter relay 2 Positive battery lead 3 Tail brake light breather hose 4 Tail brake light lead 5 Starter motor lead 6 Starting circuit cut off relay Earth lead Negative battery lead 9 Coolant reservoir breather hose Coolant reservoir hose 1 Cylinder head breather hose CABLE ROUTING SPEC y 2 Wire harness Pass the coolant reservoir hose through the hose guide Route the earth lead and wire harness under the battery bracket Connect the tail brake light lead between the coolant reservoir and the rear fender D Pass the wire harness through the notch in the rear fender Be sure that the rear fender and air filter case do not pinch the wire harness 25 CABLE ROUTING SPEC y Route the coolant reservoir breather hose so that it is not pinched by the rear fender Fasten the coolant reservoir hose and the cylin der head breather hose to the frame with the plastic beaded tie at its loosest position so that the hoses are not pinched Lu TAN eee CS E 26 INTRODUCTION PERIODIC MAINTENANCE CHART CHK 4o FOR THE EMISSION CONTROL SYSTEM ADJ Q PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform rec
37. in the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again D AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EBS00087 CHECKING THE BRAKE FLUID LEVEL 1 Place the vehicle on a level surface NOTE When checking the brake fluid level make sure that the top of the brake master cylinder and brake fluid reservoir is horizontal 29 de CHECKING THE BRAKE FLUID LEVEL ADJ 2 Remove Right side cover Refer to SEAT FENDERS AND FUEL TANK Manual No 5TG 28197 10 3 Check brake fluid level Below the minimum level mark 1 Add the recommended brake fluid to the proper level Recommended brake fluid DOT 4 Front brake Rear brake WARNING e Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fl
38. 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 N A Ll n AD 5 N ei lt 1 4 2 H lt WSS d gt 7 d SC CH 1N 4 el C lt d a C Y DG gt X 7 a e v V gd d d i A KR A N A 2 Y E NOS EIS 7 X E SA 4 7 We Vi a a oM Ser 6 18 When installing the fuel tank cover do not pinch the front brake hose throttle cable front brake light switch lead and throttle switch lead Route the front brake hose in front of the handle bar cover Route the clutch cable and parking brake cable in front of the handlebar cover When installing the fuel tank cover do not pinch the clutch cable parking brake cable clutch switch lead and handlebar switch lead CABLE ROUTING SPEC y Fasten the cylinder head breather hose with the holder making sure that the catch of the holder is facing upward 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 Fasten the resistor lead with the holder N A NM j ni N ei lt 1 i 2 lt WSS d gt 7 e CD
39. iper EBS00427 DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS 1 Remove brake caliper pistons e dust seals 1 caliper piston seals 2 Front Rear Blow compressed air into the hose joint opening to force out the caliper piston from the brake caliper body A WARNING Never try to pry out the caliper piston Cover the caliper piston with a rag Be careful not to get injured when the piston is expelled from the caliper cylinder b Remove the caliper piston seals AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 61 FRONT AND REAR BRAKES CHAS 56 EBS00429 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Piston seals dust Replace when Brake fluid brakes are disassembled A WARNING All internal brake components should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort 1 Check brake caliper pistons 1 Scratches rust wear Replace the brake caliper assembly brake caliper cylinders 2 Wear scratches Replace the brake cali per assembly brake caliper body 3 Cracks damage Replace brake fluid delivery passage brake caliper body Blockage Blow out with compressed air A WARNING Replace the caliper piston seals and dust seals whenever the brake caliper is disas sembled Front Rear
40. journal to camshaft cap clearance Camshaft lobe dimensions Intake Exhaust Camshaft runout limit Piston Piston to cylinder clearance Piston size D Measuring point H Piston offset Offset direction Piston pin bore inside diameter Chain drive Left 22 000 22 021 mm 0 8661 0 8670 in 21 959 21 972 mm 0 8645 0 8650 in 0 028 0 062 mm 0 0011 0 0024 in 31 200 31 300 mm 1 2283 1 2323 in 22 550 22 650 mm 0 8878 0 8917 in 30 950 31 050 mm 1 2185 1 2224 in 22 494 22 594 mm 0 8856 0 8895 in 0 040 0 065 mm 0 0016 0 0026 in 94 945 94 960 mm 3 7380 3 7386 in 10 mm 0 39 in 1 0 mm 0 0394 in Intake side 20 004 20 015 mm 0 7876 0 7880 in 0 080 mm 0 0032 in 31 100 mm 1 2244 in 22 450 mm 0 8839 in 30 850 mm 1 2146 in 22 394 mm 0 8817 in 0 03 mm 0 0012 in 0 15 mm 0 0059 in 20 045 mm 0 789 in ENGINE SPECIFICATIONS SPEC y Standard Oil ring Dimensions B x T End gap installed Side clearance ER 2 0 x 2 9 mm 0 079 x 0 114 in 0 20 0 50 mm 0 008 0 020 in 0 040 0 140 mm 0 0016 0 0055 in Piston pin outside diameter 19 991 20 000 mm 0 7870 0 7874 in 19 971 mm 0 786 in Piston pin to piston pin bore clear 0 004 0 024 mm 0 0002 0 0009 in 0 074 mm ance 0 0029 in Piston rings Top ring BER HET Type Barrel _ Dimensions B x T 1 2 x 3 5 mm 0 047 x 0 138 in
41. m kg 5 1 ft Ib 55 Nm 5 5 kg 40 ft Ib Job Part Remarks Removing the swingarm and drive Remove the parts in the order listed chain Rear axle hub Refer to REAR AXLE AND REAR AXLE shock absorber Refer to REAR SHOCK ABSORBER AND RELAY ARM Swingarm skid plate Pivot shaft nut washer Pivot shaft Swingarm Drive chain guide 1 Drive sprocket cover 70 SWINGARM AND DRIVE CHAIN CHAS 36 X 100 Nm 10 0 kg 72 ft Ib 19 Nm 1 9 m kg 13 ft Ib 75 Nm 7 5 kg 54 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 55 Nm 5 5 kg 40 ft Ib Job Part Remarks 7 Drive chain guide 2 Nut Lock washer Drive sprocket Drive chain Dust cover washer bearing Spacer Oil seal Bushing Refer to INSTALLING THE DRIVEN SPROCKET Refer to INSTALLING THE SWING ARM Manual No 5TG 28197 10 For installation reverse the removal pro cedure ra es ELECTRICAL COMPONENTS ELEC EBS00500 ELECTRICAL ELECTRICAL COMPONENTS CD Main switch Starter relay 2 Throttle switch 9 Starting circuit cut off relay 3 Front brake light switch Tail brake light 4 Indicator lights 1 Battery 5 Clutch switch 2 Ignition coil 6 Handlebar switch 3 Spark plug Fuse Throttle position sensor ayy 72 ELECTRICAL COMPONENTS ELEC 5 Carburetor switch Thermo switch 2 7 Pickup coil stator assembly Neutral switch Rear brake li
42. nce is felt g Turn it 1 8 counterclockwise h Tighten the locknut 1 Locknut 25 16 Nm 1 6 m kg 11 ft Ib i Set the parking brake lever and wait more than 5 minutes j Release the parking brake lever k Slide the rubber cover to its original posi tion WARNING After this adjustment is performed lift the rear wheels off the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again AA4AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA 65 STEERING SYSTEM CHAS 36 STEERING SYSTEM INSTALLING THE HANDLEBAR 1 Install handlebar e handlebar holders NOTE Install the handlebar at a 6 angle to the hori zontal line shown in the illustration e The upper handlebar holders should be installed with the punched mark 1 forward 2 CAUTION First tighten the bolt 3 on the front side of the handlebar holders and then tighten the bolt 2 on the rear side 66 REAR SHOCK ABSORBER AND RELAY ARM CHAS 56 EBS00484 REAR SHOCK ABSORBER AND RELAY ARM 7 80 Nm 8 0 kg 58 ft Ib Ov 55 Nm 5 5 kg 40 ft Ib X ZONE 7 7 dy Removing the rear shock absorber Remove the parts in the order listed and relay arm Seat Refer to SEAT FENDERS AND FUEL TANK in chapter Manual No 5TG 28197 10 Rear axle h
43. nual No 5TG 28197 10 Refer to CLUTCH in chapter 4 Manual No 5TG 28197 10 WATER PUMP coo S a 20 Nm 2 0 kg 14 ft Ib 10 Nm 1 0 kg 7 2 ft Ib 1 Parking brake holder Oil delivery pipe 1 Oil pipe 1 Water pump breather hose Right crankcase cover Gasket Impeller Washer Impeller shaft Oil seal Bearing Oil seal sch wech sch sesch sesch sesch For installation reverse the removal pro cedure 43 FRONT AND REAR WHEELS CHAS 36 CHASSIS FRONT AND REAR WHEELS REAR WHEELS 45 Nm 4 5 m kg 32 ft Ib DS Removing the rear wheels Remove the parts in the order listed Place the vehicle on a level surface A WARNING Securely support the vehicle so there is no danger of it falling over Rear wheel Cotter pin Axle nut Wheel hub Refer to INSTALLING THE REAR WHEEL HUBS For installation reverse the removal pro cedure 44 FRONT AND REAR WHEELS CHAS 36 INSTALLING THE REAR WHEEL HUBS 1 Install rear axle washers 1 rear axle nuts 2 cotter pins 3 Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel hub surfaces that contact the rear axle washers b Tighten the rear axle nuts to specification Rear axle nut 25 200 Nm 20 0 m kg 14
44. ommended 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 This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale All service technicians should be familiar with this entire chapter PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM NOTE For ATVs not equipped with an odometer or an hour meter follow the month maintenance inter vals For ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance intervals 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 INITIAL EVERY Whichever ROUTINE comes first km 320 1300 2500 2500 5000 gt Co lt a 600 600 m x Check fuel hose for cracks or damage Replace if necessary Check condition Spark plug Adjust gap and clean Replace if necessary Check valve clearance Valves ER Adjust if necessary Carburetor Check starter choke operation e Adjust engine idle speed BEE breather Check breather hose for cracks or damage BEE Replace if necessary Check for leakage Ex
45. or Remove the parts in the order listed Seat fuel tank cover side covers left Refer to SEAT FENDERS AND FUEL and right front fender TANK in chapter Manual No 5TG 28197 10 Coolant Drain 1 Plastic band 1 2 Radiator fan coupler 1 Disconnect 3 Thermo switch 1 coupler 1 Disconnect 4 Thermo switch 1 1 5 Thermo switch 2 coupler 1 Disconnect 6 Thermo switch 2 1 7 Radiator fan breather hose 1 8 Coolant reservoir hose 1 9 Radiator outlet hose 1 10 Radiator inlet hose 1 40 COOL For installation reverse the removal pro SOE AAA 4 AM RADIATOR 9 Nm 0 9 kg 6 5 ft Ib 7 Nm 0 7 kg 5 1 ft Ib 28 Nm 2 8 kg 20 ft Ib 7 Nm 0 7 kg 5 1 ft Ib QUANT 55 Job Part Radiator grill Radiator fan Coolant reservoir breather hose Coolant reservoir cap Coolant reservoir Radiator 41 EBS00134 WATER PUMP 4 Job Part Removing the water pump Engine oil Coolant Exhaust pipe Rear brake light switch footrest right Clutch cover Radiator outlet hose Water pump inlet pipe Water pump housing Oil filter element cover Oil filter element 42 WATER PUMP coo S gt 20 Nm 2 0 m kg 14 ft Ib Remove the parts in the order listed Drain Drain Refer to ENGINE REMOVAL in chapter 4 Manual No 5TG 28197 10 Refer to FRONT AND REAR BRAKES in chapter 7 Ma
46. pecification Replace tail brake light iL MES 4 ER This circuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty and must be replaced 81 COOLING system ELEC COOLING SYSTEM CIRCUIT DIAGRAM EBS00532 m Mov18 Mov18 Qa 4h Lm Oeil s Ee v 1 o 8 am 3 Main switch 4 Battery 5 Fuse 82 7 Circuit breaker fan motor Thermo switch 1 Fan motor COOLING system ELEC EBS01085 EBS01044 TROUBLESHOOTING The radiator fan motor fails to turn e Check the condition of the battery Check Refer to CHECKING AND CHARGING 1 fuse THE BATTERY in chapter 3 2 battery Manual No 5TG 28197 10 3 main switch Minimum open circuit voltage 4 radiator fan motor ri 12 8 V or more at 20 C 68 F 5 circuit breaker fan motor 6 thermo switch 1 7 Wiring connections J YES 4 NO the entire cooling system NOTE Before troubleshooting remove the following e Clean the battery part s terminals 1 seat Recharge or 2 fuel tank cover replace the battery 3 side covers left and right 4 front fender Troubleshoot with the following special 3 Main switch tool s
47. place the handle bar switch 77 500776 5 Lighting coil resistance Disconnect the A C magneto coupler from the wire harness Connect the pocket tester Q x 1 to the lighting coil terminals as shown Positive tester probe yellow 1 Negative tester probe ground 2 e Measure the lighting coil resistance Lighting coil resistance 0 224 0 336 at 20 C 68 F n Is the lighting coil OK YES Replace the pickup coil stator assembly LIGHTING SYSTEM ELEC 6 Headlight relay 1 Remove the headlight relay 1 Connect the pocket tester Q x 1 and bat tery 12 V to the headlight relay 1 terminal as shown Check the headlight relay 1 for continuity Positive tester probe green red 1 Negative tester probe gt gt green X Positive battery terminal yellow white 3 Negative battery terminal black 4 Positive tester probe green red 5 Negative tester probe yellow 6 Does the headlight relay 1 have continuity between green red and green or yellow YES E NO Replace the head light relay 1 78 7 Headlight relay 2 Remove the headlight relay 2 Connect the pocket tester Q x 1 and bat tery 12 V to the headlight relay 2 terminal as shown Check the headlight relay 2 for continuity Positive tester probe yellow red 1 Negative tester probe yellow blue 2 M Positi
48. relay 1 Model manufacturer Coil resistance Headlight relay 2 Model manufacturer Coil resistance Thermo switch Thermo switch 1 Model manufacturer Opening temperature Closing temperature Thermo switch 2 Model manufacturer Opening temperature Closing temperature G8HN 1C4T DJ Y52 OMRON 94 5 115 50 G8HN 1C4T DJ Y52 OMRON 94 5 Q 115 50 5EB NIPPON THERMOSTAT 102 108 C 215 6 226 4 F 97 103 C 206 6 217 4 F 5LP NIPPON THERMOSTAT 117 123 C 242 6 253 4 F 112 118 C 233 6 244 4 F TIGHTENING TORQUES SPEC y EBS01005 TIGHTENING TORQUES ENGINE TIGHTENING TORQUES op ES F Thread Tightening torque Tightening torque E art to be tightene art name emarks size kee Cylinder head blind plug screw Screw Cylinder head exhaust pipe Stud bolt Oil pump housing cover Screw Oil filter cover Bolt Exhaust pipe Nut Stator coil Screw EBS01006 CHASSIS TIGHTENING TORQUES Tightening torque Tightening torque Part to be tightened Thread size Remarks i EU Eu Rear axle pinch bolt Guide pin and swingarm Front shock absorber and lower front arm Front shock absorber and frame Tie rod end and locknut Rear axle and rear wheel hub Rear brake caliper and brake caliper bracket Driven sprocket and sprocket bracket Parking brake bracket spring bracket and rear brake caliper Rear axle ring nut Rear brake disc and brake disc bracket Rear brake hose holder an
49. retor switch 7 Circuit breaker fan motor Thermo switch 1 Fan motor 09 Coolant temperature warning light 2 Neutral indicator light 02 Neutral switch 3 Diode 2 4 Thermo switch 2 0 Handlebar switch 69 Light switch 6 Engine stop switch Start switch 09 Headlight Headlight relay 1 2 Headlight relay 2 82 Resistor 83 Tail brake light 64 Rear brake light switch 65 Front brake light switch COLOR CODE Black lE Brown Green Blue Orange RT Hed OD S eons Sky blue White b Yellow BE us Black Blue B Y Black Yellow 22 Brown Blue G R Green Red Bi cius Blue Black R B Hed Black R W Hed White W B White Black White Blue YIB uses Yellow Black K i m Yellow Blue YIR eie Yellow Red YAN uis Yellow White YAMAHA YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A YFZ450V WIRING DIAGRAM O W B BLACK BLACK es hy i EA a ect st re s ech Zeg Br L Br BLACK BLACK
50. sure friction plate 1 thickness friction plate 2 thickness Out of specification Replace the friction plates as a set NOTE Measure the friction plate at four places 8 Job Part Remarks Removing the clutch Remove the parts in the order listed Engine oil Drain Clutch cable Refer to LEADS CABLES AND HOSES Refer to REMOVING THE CLUTCH and INSTALLING THE CLUTCH Clutch cover Gasket Dowel pin Clutch spring Pressure plate Push rod 1 Circlip Plain washer Bearing Ball Friction plate 1 thickness 2 9 3 1 mm 0 114 0 122 in lt Limit gt 2 8 mm 0 110 in Friction plate 2 thickness 2 9 3 1 mm 0 114 0 122 in Refer to INSTALLING THE CLUTCH lt Limit gt 2 8 mm 0 110 in 1 2 3 4 5 6 7 8 9 on sch gpa a e EBS00006 SYMBOLS The following symbols are not relevant to every vehicle Symbols 1 to 9 indicate the subject of each chapter D General information Specifications 3 Periodic checks and adjustments 2 Engine 5 Cooling system 6 Carburetor 7 Chassis Electrical 9 Troubleshooting Symbols 9 to 7 indicate the following Serviceable with engine mounted 1 Filling fluid 2 Lubricant 3 Special tool Tightening torque 5 Wear limit clearance Engine speed Electrical data Q V A Symbols to 63 in the exploded diagrams indicate the types of lubricants and lubrication points
51. t Refer to INSTALLING THE DRIVEN SPROCKET Remarks Refer to REMOVING THE REAR AXLE Circlip Brake caliper bracket Spacer Rear axle hub Oil seal Bearing Bearing Spacer N NM sech For installation reverse the removal pro cedure 47 REAR AXLE AND REAR AXLE HUB CHAS 36 REMOVING THE REAR BRAKE CALIPER 1 Remove rear brake caliper mounting bolts NOTES lll If the rear brake caliper can not be removed easily first remove the brake pads and then remove the rear brake caliper EBS00393 REMOVING THE REAR AXLE 1 Place the vehicle on a level surface 2 Remove rear axle ring nut set bolts 1 3 Loosen e rear axle ring nut 2 Apply the brake pedal so that the rear axle does not turn when loosening the rear axle ring nut Use the rear axle nut wrench 46 mm 3 Rear axle nut wrench 46 mm P N YM 37134 90890 01498 4 Loosen e driven chain Hefer to ADJUSTING THE DRIVE CHAIN SLACK 5 Elevate the rear wheels by placing the suit able stand under the frame 6 Remove rear wheels wheel hubs e nuts e washers 48 REAR AXLE AND REAR AXLE HUB CHAS 56 7 Remove rear axle 1 with driven sprocket CAUTION Never directly tap the axle end with a hammer since this will result in damage to the axle threa
52. tandard 11 clicks out Minimum 20 clicks out Maximum 1 click out CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA EBSOO 1 11 ADJUSTING THE REAR SHOCK ABSORBER 1 Remove seat Refer to SEAT FENDERS AND FUEL TANK Manual No 5TG 28197 10 2 Loosen the clamp screw 1 and then dis connect the air intake duct 34 4o ADJUSTING THE REAR SHOCK ABSORBER ADJ 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 a Elevate the rear wheels by placing able stand under the frame b Loosen the locknut 1 c Turn the adjusting ring in direction or p Spring preload is Direction increased suspension is harder Spring preload is Direction b decreased suspension is softer 1 NT w Adjusting length Standard 257mm 10 12 in Minimum 250 mm 9 84 in Maximum 264 mm 10 39 in 1 A UI A 2 cfe co op SH Be sure to 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
53. tinuity at the temperatures indicated below Coolanttemperature Continu Thermo switch ity Less than 105 3 C 221 0 5 4 F More than 105 3 C 221 0 5 4 F More than 100 3 C 212 0 5 4 F Less than 100 3 212 0 5 4 F Steps 1 amp 2 Heating phase Steps 3 amp 4 Cooling phase COOLING system ELEC A WARNING Handle the thermo switch with special care e Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it Thermo switch 1 28 Nm 2 8 m kg 20 ft Ib The thermo switch circuit is open and the radia tor fan is off The thermo switch circuit is closed and the radiator fan is on 105 3 C 212 5 4 E 221 5 4 E Does the thermo switch 1 operate properly as described above YES Replace the thermo switch 1 EBS01090 7 Wiring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM 5 the cooling system s wiring properly connected and without defects YES This circuit is OK 2 Properly connect or repair the cooling system s wiring 85 YFZ450V WIRING DIAGRAM CD A C magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor Diode 1 9 Starting circuit cut off relay Clutch switch 42 C D I unit 2 Ignition coil 3 Spark plug Throttle position sensor 5 Throttle switch Carbu
54. ub Refer to REAR AXLE AND REAR AXLE 1 Self locking nut bolt 2 Self locking nut bolt 3 Connecting arm 4 Bearing oil seal spacer Refer to INSTALLING THE RELAY ARM AND CONNECTING ARM 5 Cotter pin 67 REAR SHOCK ABSORBER AND RELAY ARM CHAS 56 7 80 Nm 8 0 kg 58 ft Ib 7 KS AV 55 Nm 5 5 kg 40 ft Ib qp 0 RE Bolt washer Refer to REMOVING THE REAR Self locking nut bolt washer SHOCK ABSORBER and INSTALL Rear shock absorber ING THE REAR SHOCK ABSORBER Manual No 5TG 28197 10 Dust seal bearing spacer Self locking nut bolt Relay arm Dust cover Spacer bearing oil seal Spacer bearing oil seal Spacer bearing oil seal Refer to INSTALLING THE RELAY ARM AND CONNECTING ARM For installation reverse the removal pro cedure 68 REAR SHOCK ABSORBER AND RELAY ARM CHAS 56 EBS00490 INSTALLING THE RELAY ARM AND CONNECTING ARM 1 Install bearings 1 to connecting arm Installed depth of bearing 4 mm 0 16 in 2 Install bearings to 3 to relay arm Installed depth of bearing 5 0 mm 0 20 in Installed depth of bearing 5 0 mm 0 20 in Installed depth of bearing 4 6 mm 0 18 in 69 SWINGARM AND DRIVE CHAIN CHAS 36 EBS00492 SWINGARM AND DRIVE CHAIN X 100 Nm 10 0 kg 72 ft Ib 19 Nm 1 9 m kg 13 ft Ib X 75 Nm 7 5 kg 54 ft Ib 7 Nm 0 7
55. uid level make sure that the top of the brake master cylinder and brake fluid reservoir is horizontal 30 CHK 4o ADJUSTING THE DRIVE CHAIN SLACK ADJ ADJUSTING THE DRIVE CHAIN SLACK NOTE Measure the drive chain slack halfway between the drive axle and the rear axle CAUTION A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swingarm or cause an accident Therefore keep the drive chain slack within the speci fied limits 1 Measure drive chain slack Out of specification Adjust Drive chain slack 25 35 mm 0 98 1 38 in 2 Adjust e drive chain slack NOTE AAA The drive chain slack is adjusted by the rota tion of the rear axle hub a Loosen the rear axle pinch bolts 1 Loosen the rear axle pinch bolts the proper sequence as shown b Insert an appropriate shaft in the hole of rear axle hub 4 c Shift the transmission into the neutral posi tion d To loosen the drive chain push the vehicle forward and to tighten the drive chain pull the vehicle backward CAUTION Excessive chain slack will overload the engine and other vital parts keep the slack within the specified limits 81 ADJUSTING THE DRIVE CHAIN SLACK CHK ADJUSTING THE FRONT SHOCK ABSORBERS ADJ Q AX RAVA
56. umbers 5 are 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 7 accompanies 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 8 are given in addition to the exploded diagram and the job instruction chart D CLUTCH ENG CEUTCH 500291 me CLUTCH REMOVING THE CLUTCH 3 1 Remove clutch cover 1 Loosen each bolt 1 4 of a turn at time in tages and in a crisscross pattern After all of 10 Nm 1 0 m kg 7 2 ft Ib 5 mom Mg the bolts are fully loosened remove them Pa d 2 Straighten the lock washer tab 3 Loosen 8 clutch boss nut D NOTE While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Universal clutch holder P N YM 91042 90890 04086 500300 5 The following procedure applies to all of the friction plates 1 Check friction plate 1 friction plate 2 Damage wear Replace the friction plates as a set Mea
57. ve battery terminal blue 3 Negative battery terminal black 4 Positive tester probe gt yellow red 5 Negative tester probe green red 6 Does the headlight relay 2 have continuity between yellow red and yellow blue or green red YES J NO Replace the head light relay 2 LIGHTING system ELEC 8 Resistor resistance Disconnect the resistor coupler from the wire harness Connect the pocket tester Q x 1 to the resistor coupler as shown Positive tester probe black 1 Negative tester probe black e Measure the resistor resistance Resistor resistance 2 755 3 045 at 25 C 77 F NO Replace the resistor 5 the resistor OK YES 79 LIGHTING System ELEC 2 Voltage Connect the pocket tester AC 20 V to the headlight couplers as shown When the light switch is set to LO When the light switch is set to HI 501069 9 Wiring Check the entire lighting system s wiring Refer to CIRCUIT DIAGRAM 5 the lighting system s wiring properly connected and without defects YES Check the condition Properly connect or of each of the lighting repair the lighting system s circuits system s wiring Refer to CHECK ING THE LIGHTING SYSTEM Headlight coupler wire harness side Headlight Positive tester probe yellow 1 or green 2 Negative tester probe black 3 EBSO10

2006 YFZ450 Service Manual Supplement

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