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General| Engine Type | 449cc liquid-cooled DOHC 4-stroke; 4 titanium valves |
|---|---|
| Bore x Stroke | 97.0mm x 60.8mm |
| Compression Ratio | 12.5:1 |
| Fuel Delivery | Fuel Injection |
| Ignition | TCI: Transistor Controlled Ignition |
| Final Drive | Chain |
| Brakes / Front | Hydraulic single disc brake, 250mm |
| Brakes / Rear | Hydraulic single disc brake, 245mm |
| Tires / Front | 80/100-21 |
| Tires / Rear | 120/80-19 |
| Width | 32.5 in |
| Seat Height | 38.0 in |
| Wheelbase | 58.7 in |
| Ground Clearance | 13.2 in |
| Fuel Capacity | 2.0 gal |
| Transmission | 5-speed; multiplate wet clutch |
| Suspension / Front | KYB® Speed-Sensitive System, inverted fork; fully adjustable, 12.2-in travel |
| Suspension / Rear | Fully adjustable KYB shock; 12.4-in travel |
| Wet Weight | 245 lb |
General introduction to the Yamaha YZ series and the manual's purpose.
Crucial safety precautions and guidelines for operating the vehicle.
Instructions on how to locate specific pages within the manual.
Explanation of the manual's step-by-step procedure format.
Location and importance of the vehicle identification number.
Location and importance of the engine serial number.
Location of the model label for ordering spare parts.
Explanation of the Fuel Injection system's function and components.
Key preparation steps before removing or disassembling parts.
Procedure for checking electrical connections for stains, rust, or moisture.
Tools for checking parts for runout or bend.
Tools for installing the crankshaft.
Tool for removing the piston pin.
Tools for checking the cooling system.
Tool for tightening the steering ring nut.
Tool for checking fault codes and diagnosing problems.
Instrument for checking ignition system components.
Tool for observing engine RPM.
Sealant for crankcase mating surfaces.
Location and operation of the engine stop switch.
Location and operation of the clutch lever.
Operation of the shift pedal for gear changes.
Operation of the kickstarter crank for starting the engine.
Operation of the throttle grip for acceleration/deceleration.
Operation of the front brake lever.
Operation of the rear brake pedal.
Use of the starter knob/idle screw for cold starting.
Recommended break-in procedures for new machines.
Torque specifications for frame construction points.
Torque specifications for the exhaust system.
Torque specifications for engine mounting points.
Torque specifications for steering components.
Torque specifications for suspension components.
Torque specifications for wheel installation.
Torque specifications for brake system components.
Torque specification for the fuel pump.
Torque specifications for engine components.
Torque specifications for chassis components.
Torque specifications for electrical components.
General torque specifications and definitions of units.
Detailed instructions for cleaning the machine.
Preventive measures for storing the machine for extended periods.
Key specifications including dimensions, weight, and engine type.
Maintenance specifications for engine components like cylinder head and cylinder.
Maintenance specifications for chassis components like steering and suspension.
Maintenance specifications for electrical system components.
Torque specifications for engine components.
Torque specifications for chassis components.
Torque specifications for electrical components.
General torque specifications and definitions of units.
Recommended maintenance intervals for various components.
Pre-operation checks for fuel, oil, brakes, and other systems.
Procedure for checking the engine's coolant level.
Steps for changing the engine coolant.
Inspection of the radiator cap's seal and valve.
Inspection of the cooling system's coolant level and leaks.
Adjusting the clutch lever position for optimal engagement.
Adjusting the free play in the clutch cable.
Adjusting the free play in the throttle cable.
Procedure for cleaning the air filter element.
Procedure for checking the engine oil level.
Steps for changing the engine oil and filter.
Procedure for checking the engine oil pressure.
Adjusting the engine idle speed.
Procedure for adjusting valve clearances when the engine is cool.
Procedure for bleeding the hydraulic brake system to remove air.
Adjusting the front brake lever position.
Adjusting the rear brake pedal height.
Inspection and replacement of front brake pads.
Inspection and replacement of rear brake pads.
Procedure for checking and filling brake fluid.
Adjusting the drive chain slack to the correct specification.
Inspection of the front fork's smooth action and oil leakage.
Adjusting the front fork rebound damping force.
Adjusting the front fork compression damping force.
Inspection of the rear shock absorber's action and condition.
Adjusting the spring preload on the rear shock absorber.
Procedure for checking and adjusting tire pressure.
Checking and adjusting the steering head for proper play and smooth action.
Steps for removing, disassembling, and installing the swingarm assembly.
Steps for removing, inspecting, and installing the rear shock absorber.
Lubrication of control cables.
Lubrication of the drive chain.
Steps for checking and inspecting the spark plug.
Procedure for checking and adjusting ignition timing.
Troubleshooting guide for common engine performance issues.
Step-by-step inspection process for diagnosing engine problems.
Instructions for removing the seat and side covers.
Inspection and replacement of insulators on side covers.
Procedure for removing the number plate.
Inspection and replacement of the protector.
Steps for removing the exhaust pipe and silencer assembly.
Procedure for changing the silencer fiber for USA and CDN models.
Steps for installing the silencer and exhaust pipe.
Steps for removing the radiator.
Steps for installing the radiator and its components.
Steps for removing the cylinder head cover.
Steps for removing the camshafts.
Inspection of camshaft lobes and runout.
Steps for installing the camshafts.
Steps for removing the cylinder head.
Inspecting cylinder head for carbon deposits and warpage.
Steps for installing the cylinder head with proper torque sequence.
Steps for removing valves and valve springs.
Removing valve lifters and cotters.
Checking valve sealing, face, seat, and width.
Replacing valve guides and reaming to size.
Lapping valve faces and seats.
Measuring valve spring free length and compressed force.
Inspecting valve lifters for wear or damage.
Installing valves, seats, seals, springs, and retainers.
Steps for removing the cylinder and piston assembly.
Removing piston pin clips, pin, piston, and piston rings.
Inspecting cylinder and piston walls for scratches.
Measuring piston ring side clearance.
Installing piston rings and piston onto the cylinder.
Steps for installing the cylinder.
Steps for removing the clutch assembly.
Inspecting clutch housing and boss for cracks or wear.
Measuring friction plate thickness.
Measuring clutch plate warpage.
Steps for installing the clutch assembly.
Steps for removing the oil filter element and water pump.
Checking oil pump clearances.
Installing the oil filter element and cover.
Steps for removing the balancer.
Steps for installing the balancer and related gears.
Steps for removing the oil pump assembly.
Checking oil pump clearances.
Steps for installing the oil pump assembly.
Steps for removing kick shaft and shift shaft components.
Installing the segment.
Installing the kick shaft assembly.
Installing the kick idle gear.
Steps for removing the AC magneto.
Inspecting the AC magneto's rotor and stator surfaces.
Steps for installing the AC magneto.
Steps for removing electronic components like the ECU and ignition coil.
Steps for removing the engine from the chassis.
Steps for installing the engine into the chassis.
Installing the drive sprocket and drive chain.
Steps for removing the crankshaft.
Steps for disassembling the crankcase halves.
Measuring crankshaft runout and clearances.
Installing the crankshaft using special tools.
Steps for removing the transmission components.
Removing the main axle, drive axle, shift cam, and forks.
Inspecting gears for worn teeth or dog engagement.
Steps for installing transmission components.
Steps for removing the front wheel.
Steps for removing the rear wheel.
Checking wheel runout and bearings.
Measuring wheel axle bends.
Measuring brake disc deflection and thickness.
Steps for installing the front wheel.
Steps for installing the rear wheel.
Steps for removing the front brake system components.
Steps for removing the rear brake system components.
Disassembly of the front and rear brake calipers.
Disassembly of the front and rear brake master cylinders.
Procedure for draining the brake fluid.
Removing brake caliper pistons carefully.
Inspecting the brake master cylinder for wear or damage.
Inspecting brake hoses for cracks or damage.
Installing brake caliper pistons, seals, and dust seals.
Installing the front brake caliper assembly.
Installing the rear brake caliper assembly.
Installing the brake master cylinder kit components.
Procedure for filling the brake fluid reservoir.
Steps for removing the front fork assembly.
Disassembly of the front fork components.
Inspecting the base valve for wear, contamination, or damage.
Measuring fork spring free length.
Inspecting the inner tube for score marks or bends.
Inspecting the adjuster for wear or O-ring damage.
Steps for assembling the front fork.
Steps for installing the front fork assembly.
Steps for removing the handlebar assembly.
Inspecting the handlebar for bends or damage.
Steps for installing the handlebar.
Adjusting the clutch lever free play.
Steps for removing the steering stem and related components.
Inspecting the steering stem for bends or damage.
Inspecting bearings and races for smooth operation.
Installing the lower steering bracket.
Steps for removing the swingarm assembly.
Disassembly of the swingarm components.
Steps for installing the swingarm assembly.
Steps for removing the rear shock absorber.
Inspecting damper rod, spring, spring guide, and bearings.
Installing the rear shock absorber spring and guides.
Installing the rear shock absorber assembly.
Steps for removing, inspecting, and installing the fuel tank and pump.
Measuring fuel pressure with a gauge.
Steps for removing the throttle body assembly.
Disassembly of the throttle body components.
Checking the throttle body for cracks or damage.
Steps for installing the throttle body assembly.
Listing and numbering of electrical components on the vehicle.
Diagram showing the electrical system wiring with color codes.
Steps for troubleshooting ignition system failures and spark plug issues.
Procedure for testing spark gap and ignition.
Checking primary and secondary coil resistance.
Checking the ECU's installation status and components.
Inspection steps if the throttle position sensor is not operating correctly.
Inspecting throttle position sensor resistance.
Replacing and adjusting the throttle position sensor.
Checking the input voltage to the throttle position sensor.
Troubleshooting guide for FI system problems.
Connecting the FI diagnostic tool for system checks.
Procedure for checking fault codes displayed by the FI diagnostic tool.
Setting the diagnostic mode on the FI diagnostic tool.
Table detailing sensor operations and checking methods.
Troubleshooting steps for various fault codes related to engine sensors.
Inspection steps if the fuel pump is not operating normally.
Checking the coolant temperature sensor resistance.
Checking the intake air pressure sensor output voltage.
Checking the intake air temperature sensor resistance.
Checking the atmospheric pressure sensor output voltage.
Checking fuel injector resistance and operation.
Checking rectifier/regulator output voltage.
Adjustments for engine and suspension tuning.
Parts related to front fork setting, including springs.
Factors affecting rear suspension setting: spring preload and damping.
Procedure for measuring and setting the rear spring length.
Adjusting springs after replacement for optimal performance.
Troubleshooting and adjustment guide for front fork suspension symptoms.
Troubleshooting and adjustment guide for rear shock absorber suspension symptoms.
