Yamaha YZ450F Manuals

Manuals and User Guides for Yamaha YZ450F. We have 5 Yamaha YZ450F manuals available for free PDF download: Owner's Service Manual, Parts Catalogue

YAMAHA YZ450F Owner's Service Manual

YAMAHA YZ450F Owner's Service Manual (642 pages)

Brand: YAMAHA | Category: Motorcycle | Size: 30.33 MB
Table of contents
Important Notice6................................................................................................................................................................
Description12................................................................................................................................................................
Chapitre13................................................................................................................................................................
Table Of Contents20................................................................................................................................................................
Engine26................................................................................................................................................................
Allgemeine Angaben27................................................................................................................................................................
Machine Identification28................................................................................................................................................................
Identification De La Machine29................................................................................................................................................................
Important Information30................................................................................................................................................................
Wichtige Informationen31................................................................................................................................................................
Informations Importantes31................................................................................................................................................................
Checking Of Connection36................................................................................................................................................................
Verification Des Connexions37................................................................................................................................................................
Special Tools38................................................................................................................................................................
Outils Speciaux41................................................................................................................................................................
Control Functions48................................................................................................................................................................
Fonctions Des Commandes49................................................................................................................................................................
Fuel50................................................................................................................................................................
Starting And Break-in56................................................................................................................................................................
Anlassen Und Einfahren57................................................................................................................................................................
Mise En Marche Et Rodage57................................................................................................................................................................
Torque-check Points62................................................................................................................................................................
Points De Verification De Couple De Serrage65................................................................................................................................................................
Anzugsmomente Kontrollieren66................................................................................................................................................................
Cleaning And Storage68................................................................................................................................................................
Reinigung Und Stillegung69................................................................................................................................................................
Nettoyage Et Rangement69................................................................................................................................................................
Essence71................................................................................................................................................................
General Specifications72................................................................................................................................................................
Chassis73................................................................................................................................................................
Maintenance Specifications75................................................................................................................................................................
General Torque Specifications89................................................................................................................................................................
Definition Of Units89................................................................................................................................................................
Caracteristiques Generales90................................................................................................................................................................
Caracteristiques Generales De Couple107................................................................................................................................................................
Definition Des Unites107................................................................................................................................................................
Kraftstoff108................................................................................................................................................................
Allgemeine Technische Daten109................................................................................................................................................................
Allgemeine Anzugsmomente125................................................................................................................................................................
Lubrication Diagrams126................................................................................................................................................................
Cable Routing Diagram130................................................................................................................................................................
Cheminement Des Cables131................................................................................................................................................................
KabelfÜhrung131................................................................................................................................................................
Maintenance Intervals142................................................................................................................................................................
Wartungsintervalle Und Schmierdienst148................................................................................................................................................................
Pre-operation Inspection And Maintenance151................................................................................................................................................................
Engine Oil Replacement176................................................................................................................................................................
And Side Covers180................................................................................................................................................................
Valve Clearance Adjustment190................................................................................................................................................................
Partie Cycle195................................................................................................................................................................
Rear Brake Adjustment198................................................................................................................................................................
Front Wheel And Rear Wheel202................................................................................................................................................................
Rear Shock Absorber Inspection218................................................................................................................................................................
Electrical236................................................................................................................................................................
Moteur237................................................................................................................................................................
Exhaust Pipe And Silencer244................................................................................................................................................................
Radiator248................................................................................................................................................................
Carburetor254................................................................................................................................................................
Camshafts280................................................................................................................................................................
Cylinder Head280................................................................................................................................................................
Arbre A Cames281................................................................................................................................................................
Arbres A Cames283................................................................................................................................................................
Valves And Valve Springs304................................................................................................................................................................
Soupapes Et Ressorts De Soupape305................................................................................................................................................................
Ventile Und Ventilfedern305................................................................................................................................................................
Cylinder And Piston322................................................................................................................................................................
Cylindre Et Piston323................................................................................................................................................................
Zylinder Und Kolben323................................................................................................................................................................
Clutch334................................................................................................................................................................
Oil Filter, Water Pump And Crankcase Cover (right)348................................................................................................................................................................
Balancer356................................................................................................................................................................
Oil Pump368................................................................................................................................................................
Pompe A Huile369................................................................................................................................................................
Kick Axle And Shift Shaft376................................................................................................................................................................
Cdi Magneto390................................................................................................................................................................
Magneto Cdi391................................................................................................................................................................
Engine Removal398................................................................................................................................................................
Depose Du Moteur399................................................................................................................................................................
Motor Demontieren399................................................................................................................................................................
Crankcase And Crankshaft408................................................................................................................................................................
Carter Et Vilebrequin409................................................................................................................................................................
Transmission, Shift Cam And Shift Fork412................................................................................................................................................................
Roue Avant Et Roue Arriere439................................................................................................................................................................
Front Brake And Rear Brake454................................................................................................................................................................
Frein Avant Et Frein Arriere455................................................................................................................................................................
Front Fork470................................................................................................................................................................
Handlebar486................................................................................................................................................................
Fourche Avant487................................................................................................................................................................
Steering522................................................................................................................................................................
Swingarm534................................................................................................................................................................
Rear Shock Absorber534................................................................................................................................................................
Bras Oscillant537................................................................................................................................................................
Tuyau D'echappement Et Silencieux551................................................................................................................................................................
Amortisseur Arriere553................................................................................................................................................................
And Wiring Diagram564................................................................................................................................................................
Partie Electrique565................................................................................................................................................................
Map-controlled Cdi Unit566................................................................................................................................................................
Ignition System566................................................................................................................................................................
Bloc Cdi Controle Par Microprocesseur567................................................................................................................................................................
Carburateur585................................................................................................................................................................
Vergaser585................................................................................................................................................................
Fahrgestell615................................................................................................................................................................
Suspension Setting634................................................................................................................................................................

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Yamaha YZ450F Owner's Service Manual

Yamaha YZ450F Owner's Service Manual (362 pages)

2016  
Brand: Yamaha | Category: Motorcycle | Size: 11 MB
Table of contents
Important Manual Information6................................................................................................................................................................
Safety Information7................................................................................................................................................................
How To Use This Manual8................................................................................................................................................................
Table Of Contents11................................................................................................................................................................
General Information13................................................................................................................................................................
Location Of Important Labels15................................................................................................................................................................
Description18................................................................................................................................................................
Identification19................................................................................................................................................................
Vehicle Identification Number19................................................................................................................................................................
Engine Serial Number19................................................................................................................................................................
Included Parts20................................................................................................................................................................
Sidestand20................................................................................................................................................................
Spark Plug Wrench20................................................................................................................................................................
Nipple Wrench20................................................................................................................................................................
Handlebar Protector20................................................................................................................................................................
Fuel Hose Joint Cover20................................................................................................................................................................
Coupler For Connecting Optional Part20................................................................................................................................................................
Important Information22................................................................................................................................................................
Preparation For Removal And Disassembly22................................................................................................................................................................
Replacement Parts22................................................................................................................................................................
Gaskets, Oil Seals And O-rings23................................................................................................................................................................
Lock Washers/plates And Cotter Pins23................................................................................................................................................................
Bearings And Oil Seals23................................................................................................................................................................
Circlips23................................................................................................................................................................
Basic Service Information24................................................................................................................................................................
Electrical System24................................................................................................................................................................
Special Tools27................................................................................................................................................................
Control Functions32................................................................................................................................................................
Engine Stop Switch32................................................................................................................................................................
Launch Control Switch32................................................................................................................................................................
Clutch Lever32................................................................................................................................................................
Shift Pedal32................................................................................................................................................................
Kickstarter Lever33................................................................................................................................................................
Throttle Grip33................................................................................................................................................................
Front Brake Lever33................................................................................................................................................................
Rear Brake Pedal33................................................................................................................................................................
Starter Knob/idle Screw33................................................................................................................................................................
Fuel Tank Cap34................................................................................................................................................................
Starting And Break-in35................................................................................................................................................................
Fuel35................................................................................................................................................................
Starting A Cold Engine35................................................................................................................................................................
Starting A Warm Engine36................................................................................................................................................................
Break-in Procedures36................................................................................................................................................................
Maintenance After Break-in37................................................................................................................................................................
Major Maintenance37................................................................................................................................................................
Torque-check Points38................................................................................................................................................................
Cleaning And Storage40................................................................................................................................................................
Cleaning40................................................................................................................................................................
Storage40................................................................................................................................................................
Specifications41................................................................................................................................................................
General Specifications42................................................................................................................................................................
Engine Specifications43................................................................................................................................................................
Chassis Specifications48................................................................................................................................................................
Electrical Specifications52................................................................................................................................................................
Tightening Torques53................................................................................................................................................................
General Tightening Torque Specifications53................................................................................................................................................................
Engine Tightening Torques54................................................................................................................................................................
Chassis Tightening Torques58................................................................................................................................................................
Lubrication Points And Lubricant Types61................................................................................................................................................................
Engine61................................................................................................................................................................
Chassis62................................................................................................................................................................
Lubrication System Chart And Diagrams64................................................................................................................................................................
Lubrication Diagrams64................................................................................................................................................................
Cable Routing Diagram72................................................................................................................................................................
Periodic Checks And Adjustments83................................................................................................................................................................
Maintenance Intervals85................................................................................................................................................................
Pre-operation Inspection And Maintenance91................................................................................................................................................................
General Inspection And Maintenance91................................................................................................................................................................
Checking The Coolant Level92................................................................................................................................................................
Checking The Cooling System92................................................................................................................................................................
Changing The Coolant92................................................................................................................................................................
Checking The Radiator Cap93................................................................................................................................................................
Checking The Radiator Cap Valve Opening Pressure93................................................................................................................................................................
Checking The Coolant Circulatory System For Leaks94................................................................................................................................................................
Adjusting The Clutch Lever Position94................................................................................................................................................................
Adjusting The Clutch Lever Free Play95................................................................................................................................................................
Adjusting The Throttle Grip Free Play95................................................................................................................................................................
Lubricating The Throttle Cable96................................................................................................................................................................
Cleaning The Air Filter Element96................................................................................................................................................................
Checking The Throttle Body Joint97................................................................................................................................................................
Checking The Breather Hoses97................................................................................................................................................................
Checking The Exhaust System98................................................................................................................................................................
Checking The Fuel Line98................................................................................................................................................................
Checking The Engine Oil Level98................................................................................................................................................................
Changing The Engine Oil99................................................................................................................................................................
Adjusting The Engine Idling Speed100................................................................................................................................................................
Adjusting The Valve Clearance101................................................................................................................................................................
Bleeding The Brake System106................................................................................................................................................................
Checking The Brake Hose107................................................................................................................................................................
Adjusting The Front Brake107................................................................................................................................................................
Adjusting The Rear Brake108................................................................................................................................................................
Checking The Front Brake Pads108................................................................................................................................................................
Checking The Rear Brake Pads110................................................................................................................................................................
Checking The Rear Brake Pad Insulator111................................................................................................................................................................
Checking The Brake Fluid Level111................................................................................................................................................................
Adjusting The Drive Chain Slack112................................................................................................................................................................
Checking The Front Fork Legs113................................................................................................................................................................
Checking The Front Fork Protector Guide113................................................................................................................................................................
Cleaning The Front Fork Oil Seal And Dust Seal113................................................................................................................................................................
Air Bleeding From Front Fork114................................................................................................................................................................
Adjusting The Front Fork Legs114................................................................................................................................................................
Checking The Swingarm Operation115................................................................................................................................................................
Checking The Rear Suspension115................................................................................................................................................................
Adjusting The Rear Shock Absorber Assembly115................................................................................................................................................................
Checking The Tires118................................................................................................................................................................
Checking And Tightening The Spokes118................................................................................................................................................................
Checking The Wheels118................................................................................................................................................................
Checking The Wheel Bearings118................................................................................................................................................................
Checking And Adjusting The Steering Head119................................................................................................................................................................
Lubricating The Levers120................................................................................................................................................................
Lubricating The Pedal120................................................................................................................................................................
Checking The Spark Plug121................................................................................................................................................................
Checking The Ignition Timing121................................................................................................................................................................
General Chassis125................................................................................................................................................................
Removing The Left Side Cover126................................................................................................................................................................
Removing The Seat126................................................................................................................................................................
Removing The Number Plate126................................................................................................................................................................
Front Wheel127................................................................................................................................................................
Removing The Front Wheel128................................................................................................................................................................
Checking The Front Wheel128................................................................................................................................................................
Disassembling The Front Wheel129................................................................................................................................................................
Assembling The Front Wheel129................................................................................................................................................................
Installing The Front Wheel130................................................................................................................................................................
Rear Wheel131................................................................................................................................................................
Removing The Rear Wheel132................................................................................................................................................................
Checking The Rear Wheel132................................................................................................................................................................
Disassembling The Rear Wheel132................................................................................................................................................................
Checking And Replacing The Rear Wheel Sprocket132................................................................................................................................................................
Assembling The Rear Wheel133................................................................................................................................................................
Installing The Rear Wheel134................................................................................................................................................................
Front Brake136................................................................................................................................................................
Introduction140................................................................................................................................................................
Checking The Front Brake Disc140................................................................................................................................................................
Removing The Front Brake Caliper140................................................................................................................................................................
Disassembling The Front Brake Caliper140................................................................................................................................................................
Checking The Front Brake Caliper141................................................................................................................................................................
Assembling The Front Brake Caliper141................................................................................................................................................................
Installing The Brake Caliper Piston141................................................................................................................................................................
Installing The Front Brake Caliper142................................................................................................................................................................
Removing The Front Brake Master Cylinder143................................................................................................................................................................
Checking The Front Brake Master Cylinder143................................................................................................................................................................
Assembling The Front Brake Master Cylinder143................................................................................................................................................................
Installing The Front Brake Master Cylinder144................................................................................................................................................................
Rear Brake146................................................................................................................................................................
Checking The Rear Brake Disc150................................................................................................................................................................
Removing The Rear Brake Caliper151................................................................................................................................................................
Disassembling The Rear Brake Caliper151................................................................................................................................................................
Checking The Rear Brake Caliper151................................................................................................................................................................
Assembling The Rear Brake Caliper151................................................................................................................................................................
Installing The Rear Brake Caliper152................................................................................................................................................................
Removing The Rear Brake Master Cylinder153................................................................................................................................................................
Checking The Rear Brake Master Cylinder153................................................................................................................................................................
Assembling The Rear Brake Master Cylinder154................................................................................................................................................................
Installing The Rear Brake Master Cylinder154................................................................................................................................................................
Handlebar158................................................................................................................................................................
Removing The Handlebar158................................................................................................................................................................
Checking The Handlebar158................................................................................................................................................................
Installing The Handlebar158................................................................................................................................................................
Front Fork162................................................................................................................................................................
Removing The Front Fork Legs164................................................................................................................................................................
Disassembling The Front Fork Legs164................................................................................................................................................................
Assembling The Front Fork Legs166................................................................................................................................................................
Installing The Front Fork Legs172................................................................................................................................................................
Steering Head175................................................................................................................................................................
Removing The Lower Bracket176................................................................................................................................................................
Checking The Steering Head176................................................................................................................................................................
Installing The Steering Head176................................................................................................................................................................
Rear Shock Absorber Assembly179................................................................................................................................................................
Handling The Rear Shock Absorber182................................................................................................................................................................
Disposing Of A Rear Shock Absorber182................................................................................................................................................................
Removing The Rear Shock Absorber Assembly182................................................................................................................................................................
Removing The Bearing183................................................................................................................................................................
Checking The Rear Shock Absorber Assembly183................................................................................................................................................................
Checking The Connecting Arm And Relay Arm183................................................................................................................................................................
Installing The Relay Arm183................................................................................................................................................................
Installing The Rear Shock Absorber Assembly184................................................................................................................................................................
Swingarm186................................................................................................................................................................
Removing The Swingarm187................................................................................................................................................................
Checking The Swingarm187................................................................................................................................................................
Installing The Swingarm188................................................................................................................................................................
Chain Drive189................................................................................................................................................................
Removing The Drive Chain190................................................................................................................................................................
Checking The Drive Chain190................................................................................................................................................................
Checking The Drive Sprocket191................................................................................................................................................................
Checking The Rear Wheel Sprocket191................................................................................................................................................................
Installing The Drive Chain191................................................................................................................................................................
Engine Removal196................................................................................................................................................................
Removing The Silencer201................................................................................................................................................................
Removing The Exhaust Pipe 2201................................................................................................................................................................
Removing The Drive Sprocket201................................................................................................................................................................
Removing The Engine202................................................................................................................................................................
Checking The Silencer And Exhaust Pipe202................................................................................................................................................................
Changing The Silencer Fiber202................................................................................................................................................................
Installing The Engine203................................................................................................................................................................
Installing The Brake Pedal204................................................................................................................................................................
Installing The Drive Sprocket204................................................................................................................................................................
Installing The Exhaust Pipe And Muffler205................................................................................................................................................................
Camshaft207................................................................................................................................................................
Removing The Camshaft209................................................................................................................................................................
Checking The Camshaft210................................................................................................................................................................
Checking The Timing Chain And Camshaft Sprocket211................................................................................................................................................................
Checking The Timing Chain Tensioners211................................................................................................................................................................
Checking The Decompression System212................................................................................................................................................................
Installing The Camshafts212................................................................................................................................................................
Cylinder Head215................................................................................................................................................................
Removing The Cylinder Head217................................................................................................................................................................
Checking The Timing Chain Guide (intake Side)217................................................................................................................................................................
Checking The Cylinder Head217................................................................................................................................................................
Installing The Cylinder Head218................................................................................................................................................................
Valves And Valve Springs221................................................................................................................................................................
Removing The Valves221................................................................................................................................................................
Checking The Valves And Valve Guides222................................................................................................................................................................
Checking The Valve Seats223................................................................................................................................................................
Checking The Valve Springs225................................................................................................................................................................
Checking The Valve Lifters226................................................................................................................................................................
Installing The Valves226................................................................................................................................................................
Cylinder And Piston229................................................................................................................................................................
Removing The Piston229................................................................................................................................................................
Checking The Cylinder And Piston229................................................................................................................................................................
Checking The Piston Rings230................................................................................................................................................................
Checking The Piston Pin231................................................................................................................................................................
Installing The Piston And Cylinder231................................................................................................................................................................
Clutch234................................................................................................................................................................
Removing The Clutch236................................................................................................................................................................
Checking The Friction Plates236................................................................................................................................................................
Checking The Clutch Plates236................................................................................................................................................................
Checking The Clutch Springs236................................................................................................................................................................
Checking The Clutch Housing237................................................................................................................................................................
Checking The Clutch Boss237................................................................................................................................................................
Checking The Pressure Plate237................................................................................................................................................................
Checking The Push Lever Shaft237................................................................................................................................................................
Checking The Clutch Push Rods237................................................................................................................................................................
Checking The Primary Drive Gear237................................................................................................................................................................
Checking The Primary Driven Gear238................................................................................................................................................................
Installing The Oil Seal238................................................................................................................................................................
Installing The Right Crankcase Cover238................................................................................................................................................................
Installing The Clutch239................................................................................................................................................................
Installing The Kickstarter Lever241................................................................................................................................................................
Kickstater243................................................................................................................................................................
Removing The Kick Shaft Assembly243................................................................................................................................................................
Checking The Kick Shaft And Ratchet Wheel243................................................................................................................................................................
Checking The Kick Gear, Kick Idle Gear And Ratchet Wheel243................................................................................................................................................................
Installing The Kick Shaft Assembly243................................................................................................................................................................
Installing The Kick Idle Gear244................................................................................................................................................................
Shift Shaft245................................................................................................................................................................
Removing The Shift Guide And Shift Lever Assembly247................................................................................................................................................................
Removing The Segment247................................................................................................................................................................
Checking The Shift Shaft247................................................................................................................................................................
Checking The Shift Guide And Shift Lever Assembly247................................................................................................................................................................
Checking The Stopper Lever247................................................................................................................................................................
Installing The Stopper Lever248................................................................................................................................................................
Installing The Segment248................................................................................................................................................................
Installing The Shift Guide And Shift Lever Assembly248................................................................................................................................................................
Installing The Shift Shaft249................................................................................................................................................................
Installing The Shift Pedal249................................................................................................................................................................
Oil Pump And Balancer Gear251................................................................................................................................................................
Removing The Balancer252................................................................................................................................................................
Checking The Primary Drive Gear, Balancer Shaft Drive Gear, And Balancer Weight Gear252................................................................................................................................................................
Checking The Balancer252................................................................................................................................................................
Checking The Oil Pump252................................................................................................................................................................
Assembling The Oil Pump253................................................................................................................................................................
Installing The Oil Pump And Balancer Gear254................................................................................................................................................................
Ac Magneto256................................................................................................................................................................
Removing The Ac Magneto257................................................................................................................................................................
Checking The Ac Magneto257................................................................................................................................................................
Checking The Woodruff Key257................................................................................................................................................................
Installing The Ac Magneto257................................................................................................................................................................
Crankcase259................................................................................................................................................................
Disassembling The Crankcase262................................................................................................................................................................
Removing The Crankcase Bearing262................................................................................................................................................................
Checking The Timing Chain, Timing Chain Guide, Oil Strainer262................................................................................................................................................................
Checking The Crankcase263................................................................................................................................................................
Assembling The Crankcase263................................................................................................................................................................
Crankshaft Assembly And Balancer Shaft264................................................................................................................................................................
Removing The Balancer Shaft265................................................................................................................................................................
Removing The Crankshaft Assembly265................................................................................................................................................................
Checking The Crankshaft Assembly265................................................................................................................................................................
Installing The Crankshaft Assembly266................................................................................................................................................................
Transmission267................................................................................................................................................................
Removing The Transmission268................................................................................................................................................................
Checking The Shift Forks268................................................................................................................................................................
Checking The Shift Drum Assembly269................................................................................................................................................................
Checking The Transmission269................................................................................................................................................................
Installing The Transmission269................................................................................................................................................................
Cooling System273................................................................................................................................................................
Fuel System281................................................................................................................................................................
Fuel Tank282................................................................................................................................................................
Removing The Fuel Tank283................................................................................................................................................................
Removing The Fuel Pump283................................................................................................................................................................
Checking The Fuel Pump Body283................................................................................................................................................................
Installing The Fuel Pump283................................................................................................................................................................
Installing The Fuel Tank284................................................................................................................................................................
Checking The Fuel Pressure284................................................................................................................................................................
Checking The Damper285................................................................................................................................................................
Checking And Replacing The Protector285................................................................................................................................................................
Throttle Body288................................................................................................................................................................
Checking The Injector289................................................................................................................................................................
Checking The Throttle Body289................................................................................................................................................................
Adjusting The Throttle Position Sensor290................................................................................................................................................................
Ignition System294................................................................................................................................................................
Circuit Diagram294................................................................................................................................................................
Troubleshooting296................................................................................................................................................................
Charging System298................................................................................................................................................................
Fuel Injection System302................................................................................................................................................................
Yamaha Diagnostic Tool304................................................................................................................................................................
Troubleshooting Details305................................................................................................................................................................
Fuel Pump System324................................................................................................................................................................
Electrical Components328................................................................................................................................................................
Checking The Switches330................................................................................................................................................................
Checking The Ignition Spark Gap333................................................................................................................................................................
Checking The Spark Plug Cap333................................................................................................................................................................
Checking The Ignition Coil333................................................................................................................................................................
Checking The Crankshaft Position Sensor334................................................................................................................................................................
Checking The Ecu334................................................................................................................................................................
Checking The Stator Coil334................................................................................................................................................................
Checking The Rectifier/regulator335................................................................................................................................................................
Checking The Coolant Temperature Sensor335................................................................................................................................................................
Checking The Throttle Position Sensor336................................................................................................................................................................
Checking The Throttle Position Sensor Input Voltage337................................................................................................................................................................
Checking The Intake Air Pressure Sensor337................................................................................................................................................................
Checking The Intake Air Temperature Sensor337................................................................................................................................................................
Checking The Neutral Switch338................................................................................................................................................................
Checking The Fuel Injector338................................................................................................................................................................
Starting Failures342................................................................................................................................................................
Incorrect Engine Idling Speed342................................................................................................................................................................
Poor Medium-and-high-speed Performance343................................................................................................................................................................
Shifting Is Difficult343................................................................................................................................................................
Shift Pedal Does Not Move343................................................................................................................................................................
Jumps Out Of Gear343................................................................................................................................................................
Clutch Slips343................................................................................................................................................................
Clutch Drags343................................................................................................................................................................
Overheating343................................................................................................................................................................
Overcooling344................................................................................................................................................................
Poor Braking Performance344................................................................................................................................................................
Front Fork Oil Leaking344................................................................................................................................................................
Faulty Front Fork Legs344................................................................................................................................................................
Unstable Handling344................................................................................................................................................................
List Of Self-diagnostic And Fail-safe Actions345................................................................................................................................................................
Tuning349................................................................................................................................................................
Selection Of The Secondary Reduction Ratio (sprocket)350................................................................................................................................................................
Tire Pressure351................................................................................................................................................................
Front Fork Setting351................................................................................................................................................................
Change In Amount And Characteristics Of Fork Oil351................................................................................................................................................................
Setting Of Spring After Replacement352................................................................................................................................................................
Front Fork Setting Parts352................................................................................................................................................................
Rear Suspension Setting352................................................................................................................................................................
Choosing Set Length352................................................................................................................................................................
Rear Shock Absorber Setting Parts354................................................................................................................................................................
Suspension Setting (front Fork)355................................................................................................................................................................
Suspension Setting (rear Shock Absorber)356................................................................................................................................................................
Wiring Diagram358................................................................................................................................................................
Yamaha YZ450F Owner's Service Manual

Yamaha YZ450F Owner's Service Manual (360 pages)

2015  
Brand: Yamaha | Category: Motorcycle | Size: 11.35 MB
Table of contents
Important Manual Information6................................................................................................................................................................
Safety Information7................................................................................................................................................................
How To Use This Manual8................................................................................................................................................................
Table Of Contents11................................................................................................................................................................
General Information13................................................................................................................................................................
Location Of Important Labels15................................................................................................................................................................
Description18................................................................................................................................................................
Identification19................................................................................................................................................................
Vehicle Identification Number19................................................................................................................................................................
Engine Serial Number19................................................................................................................................................................
Model Label19................................................................................................................................................................
Features20................................................................................................................................................................
Outline Of The Fi System20................................................................................................................................................................
Fi System21................................................................................................................................................................
Included Parts22................................................................................................................................................................
Sidestand22................................................................................................................................................................
Spark Plug Wrench22................................................................................................................................................................
Nipple Wrench22................................................................................................................................................................
Handlebar Protector22................................................................................................................................................................
Fuel Hose Joint Cover22................................................................................................................................................................
Coupler For Connecting Optional Part22................................................................................................................................................................
Important Information24................................................................................................................................................................
Preparation For Removal And Disassembly24................................................................................................................................................................
Replacement Parts24................................................................................................................................................................
Gaskets, Oil Seals And O-rings25................................................................................................................................................................
Lock Washers/plates And Cotter Pins25................................................................................................................................................................
Bearings And Oil Seals25................................................................................................................................................................
Circlips25................................................................................................................................................................
Basic Service Information26................................................................................................................................................................
Electrical System26................................................................................................................................................................
Special Tools29................................................................................................................................................................
Control Functions34................................................................................................................................................................
Engine Stop Switch34................................................................................................................................................................
Clutch Lever34................................................................................................................................................................
Shift Pedal34................................................................................................................................................................
Kickstarter Lever34................................................................................................................................................................
Throttle Grip34................................................................................................................................................................
Front Brake Lever34................................................................................................................................................................
Rear Brake Pedal35................................................................................................................................................................
Starter Knob/idle Screw35................................................................................................................................................................
Fuel Tank Cap35................................................................................................................................................................
Starting And Break-in36................................................................................................................................................................
Fuel36................................................................................................................................................................
Starting A Cold Engine36................................................................................................................................................................
Starting A Warm Engine37................................................................................................................................................................
Break-in Procedures37................................................................................................................................................................
Maintenance After Break-in38................................................................................................................................................................
Major Maintenance38................................................................................................................................................................
Torque-check Points39................................................................................................................................................................
Cleaning And Storage41................................................................................................................................................................
Cleaning41................................................................................................................................................................
Storage41................................................................................................................................................................
Specifications43................................................................................................................................................................
General Specifications44................................................................................................................................................................
Engine Specifications45................................................................................................................................................................
Chassis Specifications51................................................................................................................................................................
Electrical Specifications55................................................................................................................................................................
Tightening Torques56................................................................................................................................................................
General Tightening Torque Specifications56................................................................................................................................................................
Engine Tightening Torques57................................................................................................................................................................
Chassis Tightening Torques61................................................................................................................................................................
Lubrication Points And Lubricant Types64................................................................................................................................................................
Engine64................................................................................................................................................................
Chassis66................................................................................................................................................................
Lubrication System Chart And Diagrams68................................................................................................................................................................
Lubrication Diagrams68................................................................................................................................................................
Cable Routing Diagram76................................................................................................................................................................
Periodic Checks And Adjustments87................................................................................................................................................................
Maintenance Intervals89................................................................................................................................................................
Pre-operation Inspection And Maintenance95................................................................................................................................................................
General Inspection And Maintenance95................................................................................................................................................................
Checking The Coolant Level96................................................................................................................................................................
Checking The Cooling System96................................................................................................................................................................
Changing The Coolant96................................................................................................................................................................
Checking The Radiator Cap97................................................................................................................................................................
Checking The Radiator Cap Opening Pressure97................................................................................................................................................................
Checking The Coolant Circulatory System For Leaks98................................................................................................................................................................
Adjusting The Clutch Lever Position98................................................................................................................................................................
Adjusting The Clutch Lever Free Play98................................................................................................................................................................
Adjusting The Throttle Grip Free Play99................................................................................................................................................................
Lubricating The Throttle Cable100................................................................................................................................................................
Cleaning The Air Filter Element100................................................................................................................................................................
Checking The Throttle Body Joint101................................................................................................................................................................
Checking The Breather Hoses101................................................................................................................................................................
Checking The Exhaust System101................................................................................................................................................................
Checking The Fuel Line102................................................................................................................................................................
Checking The Engine Oil Level102................................................................................................................................................................
Changing The Engine Oil103................................................................................................................................................................
Adjusting The Engine Idling Speed104................................................................................................................................................................
Adjusting The Valve Clearance105................................................................................................................................................................
Bleeding The Brake System109................................................................................................................................................................
Checking The Brake Hose110................................................................................................................................................................
Adjusting The Front Brake110................................................................................................................................................................
Adjusting The Rear Brake111................................................................................................................................................................
Checking The Front Brake Pads111................................................................................................................................................................
Checking The Rear Brake Pads113................................................................................................................................................................
Checking The Rear Brake Pad Insulator114................................................................................................................................................................
Checking The Brake Fluid Level114................................................................................................................................................................
Adjusting The Drive Chain Slack115................................................................................................................................................................
Checking The Front Fork Legs116................................................................................................................................................................
Checking The Front Fork Protector Guide116................................................................................................................................................................
Cleaning The Front Fork Oil Seal And Dust Seal116................................................................................................................................................................
Air Bleeding From Front Fork116................................................................................................................................................................
Adjusting The Front Fork Legs117................................................................................................................................................................
Checking The Swingarm Operation118................................................................................................................................................................
Checking The Rear Suspension118................................................................................................................................................................
Adjusting The Rear Shock Absorber Assembly118................................................................................................................................................................
Checking The Tires120................................................................................................................................................................
Checking And Tightening The Spokes120................................................................................................................................................................
Checking The Wheels121................................................................................................................................................................
Checking The Wheel Bearings121................................................................................................................................................................
Checking And Adjusting The Steering Head121................................................................................................................................................................
Lubricating The Levers122................................................................................................................................................................
Lubricating The Pedal122................................................................................................................................................................
Checking The Spark Plug123................................................................................................................................................................
Checking The Ignition Timing123................................................................................................................................................................
General Chassis127................................................................................................................................................................
Removing The Left Side Cover128................................................................................................................................................................
Removing The Seat128................................................................................................................................................................
Removing The Number Plate128................................................................................................................................................................
Front Wheel130................................................................................................................................................................
Removing The Front Wheel130................................................................................................................................................................
Checking The Front Wheel130................................................................................................................................................................
Disassembling The Front Wheel131................................................................................................................................................................
Assembling The Front Wheel131................................................................................................................................................................
Installing The Front Wheel132................................................................................................................................................................
Rear Wheel134................................................................................................................................................................
Removing The Rear Wheel134................................................................................................................................................................
Checking The Rear Wheel134................................................................................................................................................................
Disassembling The Rear Wheel134................................................................................................................................................................
Checking And Replacing The Rear Wheel Sprocket134................................................................................................................................................................
Assembling The Rear Wheel135................................................................................................................................................................
Installing The Rear Wheel135................................................................................................................................................................
Front Brake137................................................................................................................................................................
Introduction141................................................................................................................................................................
Checking The Front Brake Disc141................................................................................................................................................................
Removing The Front Brake Caliper141................................................................................................................................................................
Disassembling The Front Brake Caliper141................................................................................................................................................................
Checking The Front Brake Caliper142................................................................................................................................................................
Assembling The Front Brake Caliper142................................................................................................................................................................
Installing The Brake Caliper Piston142................................................................................................................................................................
Installing The Front Brake Caliper143................................................................................................................................................................
Removing The Front Brake Master Cylinder144................................................................................................................................................................
Checking The Front Brake Master Cylinder144................................................................................................................................................................
Assembling The Front Brake Master Cylinder144................................................................................................................................................................
Installing The Front Brake Master Cylinder145................................................................................................................................................................
Rear Brake147................................................................................................................................................................
Checking The Rear Brake Disc151................................................................................................................................................................
Removing The Rear Brake Caliper152................................................................................................................................................................
Disassembling The Rear Brake Caliper152................................................................................................................................................................
Checking The Rear Brake Caliper152................................................................................................................................................................
Assembling The Rear Brake Caliper152................................................................................................................................................................
Installing The Rear Brake Caliper153................................................................................................................................................................
Removing The Rear Brake Master Cylinder154................................................................................................................................................................
Checking The Rear Brake Master Cylinder154................................................................................................................................................................
Assembling The Rear Brake Master Cylinder155................................................................................................................................................................
Installing The Rear Brake Master Cylinder155................................................................................................................................................................
Handlebar159................................................................................................................................................................
Removing The Handlebar159................................................................................................................................................................
Checking The Handlebar159................................................................................................................................................................
Installing The Handlebar159................................................................................................................................................................
Front Fork163................................................................................................................................................................
Removing The Front Fork Legs165................................................................................................................................................................
Disassembling The Front Fork Legs165................................................................................................................................................................
Assembling The Front Fork Legs167................................................................................................................................................................
Installing The Front Fork Legs173................................................................................................................................................................
Steering Head175................................................................................................................................................................
Removing The Lower Bracket176................................................................................................................................................................
Checking The Steering Head176................................................................................................................................................................
Installing The Steering Head176................................................................................................................................................................
Rear Shock Absorber Assembly179................................................................................................................................................................
Handling The Rear Shock Absorber182................................................................................................................................................................
Disposing Of A Rear Shock Absorber182................................................................................................................................................................
Removing The Rear Shock Absorber Assembly182................................................................................................................................................................
Removing The Bearing182................................................................................................................................................................
Checking The Rear Shock Absorber Assembly183................................................................................................................................................................
Checking The Connecting Arm And Relay Arm183................................................................................................................................................................
Installing The Relay Arm183................................................................................................................................................................
Installing The Rear Shock Absorber Assembly184................................................................................................................................................................
Swingarm186................................................................................................................................................................
Removing The Swingarm187................................................................................................................................................................
Checking The Swingarm187................................................................................................................................................................
Installing The Swingarm188................................................................................................................................................................
Chain Drive189................................................................................................................................................................
Removing The Drive Chain190................................................................................................................................................................
Checking The Drive Chain190................................................................................................................................................................
Checking The Drive Sprocket191................................................................................................................................................................
Checking The Rear Wheel Sprocket191................................................................................................................................................................
Installing The Drive Chain191................................................................................................................................................................
Engine Removal196................................................................................................................................................................
Removing The Silencer201................................................................................................................................................................
Removing The Exhaust Pipe 2201................................................................................................................................................................
Removing The Drive Sprocket201................................................................................................................................................................
Removing The Engine202................................................................................................................................................................
Checking The Silencer And Exhaust Pipe202................................................................................................................................................................
Changing The Silencer Fiber202................................................................................................................................................................
Installing The Engine203................................................................................................................................................................
Installing The Brake Pedal204................................................................................................................................................................
Installing The Drive Sprocket204................................................................................................................................................................
Installing The Exhaust Pipe And Muffler205................................................................................................................................................................
Camshaft206................................................................................................................................................................
Removing The Camshaft208................................................................................................................................................................
Checking The Camshaft209................................................................................................................................................................
Checking The Timing Chain And Camshaft Sprocket210................................................................................................................................................................
Checking The Timing Chain Tensioners210................................................................................................................................................................
Checking The Decompression System211................................................................................................................................................................
Installing The Camshafts211................................................................................................................................................................
Cylinder Head214................................................................................................................................................................
Removing The Cylinder Head216................................................................................................................................................................
Checking The Timing Chain Guide (intake Side)216................................................................................................................................................................
Checking The Cylinder Head216................................................................................................................................................................
Installing The Cylinder Head217................................................................................................................................................................
Valves And Valve Springs220................................................................................................................................................................
Removing The Valves220................................................................................................................................................................
Checking The Valves And Valve Guides221................................................................................................................................................................
Checking The Valve Seats222................................................................................................................................................................
Checking The Valve Springs224................................................................................................................................................................
Checking The Valve Lifters224................................................................................................................................................................
Installing The Valves225................................................................................................................................................................
Cylinder And Piston228................................................................................................................................................................
Removing The Piston228................................................................................................................................................................
Checking The Cylinder And Piston228................................................................................................................................................................
Checking The Piston Rings229................................................................................................................................................................
Checking The Piston Pin230................................................................................................................................................................
Installing The Piston And Cylinder230................................................................................................................................................................
Clutch233................................................................................................................................................................
Removing The Clutch235................................................................................................................................................................
Checking The Friction Plates235................................................................................................................................................................
Checking The Clutch Plates235................................................................................................................................................................
Checking The Clutch Springs235................................................................................................................................................................
Checking The Clutch Housing236................................................................................................................................................................
Checking The Clutch Boss236................................................................................................................................................................
Checking The Pressure Plate236................................................................................................................................................................
Checking The Push Lever Shaft236................................................................................................................................................................
Checking The Clutch Push Rods236................................................................................................................................................................
Checking The Primary Drive Gear236................................................................................................................................................................
Checking The Primary Driven Gear237................................................................................................................................................................
Installing The Oil Seal237................................................................................................................................................................
Installing The Right Crankcase Cover237................................................................................................................................................................
Installing The Clutch237................................................................................................................................................................
Installing The Kickstarter Lever240................................................................................................................................................................
Kickstater242................................................................................................................................................................
Removing The Kick Shaft Assembly242................................................................................................................................................................
Checking The Kick Shaft And Ratchet Wheel242................................................................................................................................................................
Checking The Kick Gear, Kick Idle Gear And Ratchet Wheel242................................................................................................................................................................
Installing The Kick Shaft Assembly242................................................................................................................................................................
Installing The Kick Idle Gear243................................................................................................................................................................
Shift Shaft244................................................................................................................................................................
Removing The Shift Guide And Shift Lever Assembly246................................................................................................................................................................
Removing The Segment246................................................................................................................................................................
Checking The Shift Shaft246................................................................................................................................................................
Checking The Shift Guide And Shift Lever Assembly246................................................................................................................................................................
Checking The Stopper Lever246................................................................................................................................................................
Installing The Stopper Lever247................................................................................................................................................................
Installing The Segment247................................................................................................................................................................
Installing The Shift Guide And Shift Lever Assembly247................................................................................................................................................................
Installing The Shift Shaft248................................................................................................................................................................
Installing The Shift Pedal248................................................................................................................................................................
Oil Pump And Balancer Gear250................................................................................................................................................................
Removing The Balancer251................................................................................................................................................................
Checking The Primary Drive Gear, Balancer Shaft Drive Gear, And Balancer Weight Gear251................................................................................................................................................................
Checking The Balancer251................................................................................................................................................................
Checking The Oil Pump251................................................................................................................................................................
Assembling The Oil Pump252................................................................................................................................................................
Installing The Oil Pump And Balancer Gear252................................................................................................................................................................
Ac Magneto254................................................................................................................................................................
Removing The Ac Magneto255................................................................................................................................................................
Checking The Ac Magneto255................................................................................................................................................................
Checking The Woodruff Key255................................................................................................................................................................
Installing The Ac Magneto255................................................................................................................................................................
Crankcase257................................................................................................................................................................
Disassembling The Crankcase260................................................................................................................................................................
Removing The Crankcase Bearing260................................................................................................................................................................
Checking The Timing Chain, Timing Chain Guide, Oil Strainer260................................................................................................................................................................
Checking The Crankcase260................................................................................................................................................................
Assembling The Crankcase261................................................................................................................................................................
Crankshaft Assembly And Balancer Shaft262................................................................................................................................................................
Removing The Balancer Shaft263................................................................................................................................................................
Removing The Crankshaft Assembly263................................................................................................................................................................
Checking The Crankshaft Assembly263................................................................................................................................................................
Installing The Crankshaft Assembly264................................................................................................................................................................
Transmission266................................................................................................................................................................
Removing The Transmission266................................................................................................................................................................
Checking The Shift Forks266................................................................................................................................................................
Checking The Shift Drum Assembly267................................................................................................................................................................
Checking The Transmission267................................................................................................................................................................
Installing The Transmission267................................................................................................................................................................
Cooling System271................................................................................................................................................................
Fuel System279................................................................................................................................................................
Fuel Tank280................................................................................................................................................................
Removing The Fuel Tank281................................................................................................................................................................
Removing The Fuel Pump281................................................................................................................................................................
Checking The Fuel Pump Body281................................................................................................................................................................
Installing The Fuel Pump281................................................................................................................................................................
Installing The Fuel Tank282................................................................................................................................................................
Checking The Fuel Pressure282................................................................................................................................................................
Checking The Damper283................................................................................................................................................................
Checking And Replacing The Protector283................................................................................................................................................................
Throttle Body284................................................................................................................................................................
Checking The Injector287................................................................................................................................................................
Checking The Throttle Body287................................................................................................................................................................
Adjusting The Throttle Position Sensor288................................................................................................................................................................
Ignition System292................................................................................................................................................................
Circuit Diagram292................................................................................................................................................................
Troubleshooting294................................................................................................................................................................
Charging System296................................................................................................................................................................
Fuel Injection System300................................................................................................................................................................
Yamaha Diagnostic Tool302................................................................................................................................................................
Troubleshooting Details303................................................................................................................................................................
Fuel Pump System322................................................................................................................................................................
Electrical Components326................................................................................................................................................................
Checking The Switches328................................................................................................................................................................
Checking The Ignition Spark Gap331................................................................................................................................................................
Checking The Spark Plug Cap331................................................................................................................................................................
Checking The Ignition Coil331................................................................................................................................................................
Checking The Crankshaft Position Sensor332................................................................................................................................................................
Checking The Ecu333................................................................................................................................................................
Checking The Stator Coil333................................................................................................................................................................
Checking The Rectifier/regulator333................................................................................................................................................................
Checking The Coolant Temperature Sensor334................................................................................................................................................................
Checking The Throttle Position Sensor334................................................................................................................................................................
Checking The Throttle Position Sensor Input Voltage335................................................................................................................................................................
Checking The Intake Air Pressure Sensor336................................................................................................................................................................
Checking The Intake Air Temperature Sensor336................................................................................................................................................................
Checking The Neutral Switch336................................................................................................................................................................
Checking The Fuel Injector337................................................................................................................................................................
Starting Failures340................................................................................................................................................................
Incorrect Engine Idling Speed340................................................................................................................................................................
Poor Medium-and-high-speed Performance341................................................................................................................................................................
Faulty Gear Shifting341................................................................................................................................................................
Shift Pedal Does Not Move341................................................................................................................................................................
Jumps Out Of Gear341................................................................................................................................................................
Faulty Clutch341................................................................................................................................................................
Overheating341................................................................................................................................................................
Overcooling342................................................................................................................................................................
Poor Braking Performance342................................................................................................................................................................
Faulty Front Fork Legs342................................................................................................................................................................
Unstable Handling342................................................................................................................................................................
List Of Self-diagnostic And Fail-safe Actions343................................................................................................................................................................
Tuning347................................................................................................................................................................
Selection Of The Secondary Reduction Ratio (sprocket)348................................................................................................................................................................
Drive And Rear Wheel Sprockets Setting Parts348................................................................................................................................................................
Tire Pressure349................................................................................................................................................................
Front Fork Setting349................................................................................................................................................................
Change In Amount And Characteristics Of Fork Oil349................................................................................................................................................................
Setting Of Spring After Replacement350................................................................................................................................................................
Front Fork Setting Parts350................................................................................................................................................................
Rear Suspension Setting350................................................................................................................................................................
Choosing Set Length350................................................................................................................................................................
Rear Shock Absorber Setting Parts352................................................................................................................................................................
Suspension Setting (front Fork)353................................................................................................................................................................
Suspension Setting (rear Shock Absorber)354................................................................................................................................................................
Wiring Diagram356................................................................................................................................................................

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Yamaha YZ450F Owner's Service Manual

Yamaha YZ450F Owner's Service Manual (230 pages)

Brand: Yamaha | Category: Motorcycle | Size: 14.53 MB
Table of contents
Safety Information6................................................................................................................................................................
Table Of Contents9................................................................................................................................................................
General Information10................................................................................................................................................................
Important Labels11................................................................................................................................................................
Location Of Important Labels14................................................................................................................................................................
Description15................................................................................................................................................................
Fuel Tank15................................................................................................................................................................
Consumer Information16................................................................................................................................................................
Features17................................................................................................................................................................
Throttle Body18................................................................................................................................................................
Included Parts19................................................................................................................................................................
Important Information19................................................................................................................................................................
Handling The Electronic Parts20................................................................................................................................................................
Checking Of Connection20................................................................................................................................................................
Special Tools22................................................................................................................................................................
Control Functions27................................................................................................................................................................
And Break-in27................................................................................................................................................................
Torque-check Points29................................................................................................................................................................
And Storage30................................................................................................................................................................
Specifications31................................................................................................................................................................
Chassis32................................................................................................................................................................
Maintenance Specifications33................................................................................................................................................................
Tightening Torques41................................................................................................................................................................
Lubrication Diagrams47................................................................................................................................................................
Cable Routing Diagram48................................................................................................................................................................
Regular Inspection And Adjustments57................................................................................................................................................................
Inspection And Maintenance61................................................................................................................................................................
Checking Coolant Level62................................................................................................................................................................
Checking Radiator Cap62................................................................................................................................................................
Engine62................................................................................................................................................................
Cleaning Air Filter64................................................................................................................................................................
Checking Throttle Body Joint65................................................................................................................................................................
Checking Fuel Line/engine Oil Level65................................................................................................................................................................
Changing Engine Oil66................................................................................................................................................................
Checking Oil Pressure66................................................................................................................................................................
Adjusting Engine Idling Speed66................................................................................................................................................................
Adjusting Valve Clearance67................................................................................................................................................................
Adjustments68................................................................................................................................................................
Electrical80................................................................................................................................................................
And Side Covers82................................................................................................................................................................
Seat And Side Covers83................................................................................................................................................................
Exhaust Pipe And Silencer84................................................................................................................................................................
Radiator88................................................................................................................................................................
Camshafts91................................................................................................................................................................
Cylinder Head96................................................................................................................................................................
Valves And Valve Springs100................................................................................................................................................................
Cylinder And Piston104................................................................................................................................................................
Clutch108................................................................................................................................................................
Oil Filter Element And Water Pump112................................................................................................................................................................
Balancer116................................................................................................................................................................
Oil Pump118................................................................................................................................................................
Kick Shaft And Shift Shaft121................................................................................................................................................................
Ac Magneto126................................................................................................................................................................
Engine Removal128................................................................................................................................................................
And Crankshaft133................................................................................................................................................................
Crankcase And Crankshaft134................................................................................................................................................................
Shift Cam And Shift Fork139................................................................................................................................................................
Front Wheel And Rear Wheel142................................................................................................................................................................
Front Brake And Rear Brake147................................................................................................................................................................
Front Fork157................................................................................................................................................................
Handlebar165................................................................................................................................................................
Steering169................................................................................................................................................................
Swingarm173................................................................................................................................................................
Shock Absorber178................................................................................................................................................................
Rear Shock Absorber179................................................................................................................................................................
Fuel System181................................................................................................................................................................
Removing/installing Fuel Pump182................................................................................................................................................................
Removing/installing Fuel Tank182................................................................................................................................................................
Components And Wiring Diagram187................................................................................................................................................................
Electrical Components And Wiring Diagram188................................................................................................................................................................
Ignition System189................................................................................................................................................................
Throttle Position Sensor System192................................................................................................................................................................
Fuel Injection System195................................................................................................................................................................
Checking The Fault Codes195................................................................................................................................................................
Fuel Pump System221................................................................................................................................................................
Electrical Components222................................................................................................................................................................
Tuning224................................................................................................................................................................
Yamaha YZ450F Parts Catalogue

Yamaha YZ450F Parts Catalogue (67 pages)

Yamaha YZ450F(V) Motorcycles Parts catalogue  
Brand: Yamaha | Category: Motorcycle | Size: 2.21 MB
Table of contents
Table Of Contents7................................................................................................................................................................
Cylinder 18................................................................................................................................................................
Carburetor19................................................................................................................................................................
Exhaust23................................................................................................................................................................
Crankcase24................................................................................................................................................................
Starter28................................................................................................................................................................
Clutch29................................................................................................................................................................
Transmission30................................................................................................................................................................
Shift Cam & Fork32................................................................................................................................................................
Shift Shaft33................................................................................................................................................................
Frame34................................................................................................................................................................
Fender36................................................................................................................................................................
Side Cover38................................................................................................................................................................
Rear Arm39................................................................................................................................................................
Rear Suspension41................................................................................................................................................................
Steering43................................................................................................................................................................
Front Fork44................................................................................................................................................................
Fuel Tank47................................................................................................................................................................
Seat49................................................................................................................................................................
Front Wheel50................................................................................................................................................................
Front Brake Caliper51................................................................................................................................................................
Rear Wheel53................................................................................................................................................................
Rear Brake Caliper54................................................................................................................................................................
Steering Handle & Cable55................................................................................................................................................................
Front Master Cylinder56................................................................................................................................................................
Stand & Footrest57................................................................................................................................................................
Rear Master Cylinder58................................................................................................................................................................
Generator59................................................................................................................................................................
Handle Switch & Lever60................................................................................................................................................................
Alternate For Chassis62................................................................................................................................................................
Alternate63................................................................................................................................................................

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