YFZ-450 / Yamaha Motor Corp., Ltd
2004-2005 Yamaha YFZ450S, YZF450T owner´s service + factory service manual
Models covered in this manual:
File specifications
File type: ZIP
Language: English
Owner´s service manual: 306 pages
Factory service manual: 355 pages
Printable: Yes
Estimated download time: 0.88 Minutes
$18.99
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Product Information
Table of Contents:
GENERAL INFORMATION
- Machine Identification
- Vehicle Identification Number
- Model Label
- Important Information
- Preparation for Removal and Disassembly
- Replacement Parts
- Gaskets, Oil Seals, and O-Rings
- Lock Washers/Plates and Cotter Pins
- Bearings and Oil Seals
- Circlips
- Checking the Connections
- Special Tools
SPECIFICATIONS
- General Specifications
- Engine Specifications
- Chassis Specifications
- Electrical Specifications
- Tightening Torques
- Engine Tightening Torques
- Chassis Tightening Torques
- How to Use the Conversion Table
- General Tightening Torque Specifications
- Lubrication Points and Lubricant Types
- Coolant Flow Diagrams
- Oil Flow Diagrams
- Cable Routing
PERIODIC CHECKS AND ADJUSTMENTS
- Introduction
- Periodic Maintenance/Lubrication
- Seat, Fenders, and Fuel Tank
- Seat, Fuel Tank Cover, and Side Covers
- Foot Protectors and Engine Skid Plate
- Headlights and Front Fender
- Rear Fender
- Fuel Tank
- Engine
- Adjusting the Valve Clearance
- Adjusting the Engine Idling Speed
- Adjusting the Throttle Lever Free Play
- Adjusting the Speed Limiter
- Checking the Spark Plug
- Checking the Ignition Timing
- Checking the Engine Oil Level
- Changing the Engine Oil
- Adjusting the Clutch Cable
- Cleaning the Air Filter Element
- Checking the Coolant Level
- Changing the Coolant
- Checking the Coolant Temperature Warning Light
- Cleaning the Spark Arrester
- Chassis
- Adjusting the Front Brake
- Adjusting the Brake Lever
- Adjusting the Rear Brake
- Adjusting the Parking Brake
- Checking the Brake Fluid Level
- Checking the Front Brake Pads
- Checking the Rear Brake Pads
- Adjusting the Rear Brake Light Switch
- Checking the Brake Hoses
- Bleeding the Hydraulic Brake System
- Adjusting the Shift Pedal
- Adjusting the Drive Chain Slack
- Checking the Steering System
- Adjusting the Toe-In
- Checking the Front and Rear Shock Absorbers
- Adjusting the Front Shock Absorbers
- Adjusting the Rear Shock Absorber
- Checking the Tires
- Checking the Wheels
- Checking and Lubricating the Cables
- Lubricating the Levers and Pedals
- Electrical System
- Checking and Charging the Battery
- Checking the Fuses
- Adjusting the Headlight Beam
- Replacing a Headlight Bulb
ENGINE
- Engine Removal
- Muffler and Exhaust Pipe
- Installing the Exhaust Pipe and Muffler
- Leads, Cables, and Hoses
- Engine Mounting Bolts
- Installing the Engine
- Camshafts
- Cylinder Head Cover
- Camshafts
- Removing the Camshafts
- Checking the Camshafts
- Checking the Camshaft Sprockets
- Checking the Decompression System
- Checking the Timing Chain Guide
- Checking the Timing Chain Tensioner
- Installing the Camshafts
- Cylinder Head
- Removing the Cylinder Head
- Checking the Cylinder Head
- Checking the Oil Delivery Pipe
- Checking the Timing Chain Guide
- Installing the Cylinder Head
- Valves and Valve Springs
- Removing the Valves and Valve Springs
- Checking the Valves and Valve Springs
- Checking the Valve Lifters
- Installing the Valves and Valve Springs
- Cylinder and Piston
- Removing the Piston
- Checking the Cylinder and Piston
- Checking the Piston Rings
- Checking the Piston Pin
- Installing the Piston
- Installing the Cylinder
- A.C. Magneto
- Removing the A.C. Magneto Rotor
- Checking the Stator Coil and Pickup Coil
- Checking the Starter Clutch
- Checking the Torque Limiter
- Installing the A.C. Magneto Rotor
- Clutch
- Removing the Clutch
- Checking the Friction Plates
- Checking the Clutch Plates
- Checking the Clutch Springs
- Checking the Clutch Housing
- Checking the Clutch Boss
- Checking the Pressure Plate
- Checking the Push Rods
- Checking the Push Lever
- Checking the Primary Driven Gear
- Installing the Clutch
- Balancer
- Removing the Balancer Drive Gear and Balancer Driven Gear
- Checking the Primary Drive Gear, Balancer Drive Gear, and Balancer Driven Gear
- Checking the Balancer
- Installing the Balancer Drive Gear and Balancer Driven Gear
- Oil Pump
- Checking the Oil Pump
- Shift Shaft
- Checking the Shift Shaft
- Checking the Stopper Lever
- Checking the Shift Guide and Shift Lever
- Checking the Shift Drum Segment
- Installing the Shift Lever
- Installing the Shift Shaft
- Crankcase
- Oil Seal and Bearing
- Separating the Crankcase
- Checking the Oil Strainer and Oil Delivery Pipe 2
- Checking the Timing Chain and Guide
- Checking the Bearings and Oil Seals
- Checking the Crankcase
- Assembling the Crankcase
- Crankshaft
- Removing the Crankshaft
- Checking the Crankshaft
- Installing the Crankshaft
- Transmission
- Main Axle
- Drive Axle
- Checking the Shift Forks
- Checking the Shift Drum
- Checking the Transmission
- Assembling the Main Axle and Drive Axle
- Installing the Transmission
COOLING SYSTEM
- Radiator
- Checking the Radiator
- Installing the Radiator
- Water Pump
- Checking the Water Pump
CARBURETOR
- Carburetor
- Disassembling the Carburetor
- Checking the Carburetor
- Assembling the Carburetor
- Adjusting the Accelerator Pump Timing
- Installing the Carburetor Joint
- Installing the Carburetor
- Checking and Adjusting the Throttle Position Sensor
CHASSIS
- Front and Rear Wheels
- Front Wheels
- Rear Wheels
- Checking the Wheels
- Checking the Wheel Hubs
- Checking the Brake Discs
- Installing the Front Wheel Hub Bearings
- Installing the Front Brake Discs
- Installing the Front Wheels
- Installing the Wheel Hubs
- Rear Axle and Rear Axle Hub
- Removing the Rear Axle
- Checking the Rear Axle
- Checking the Driven Sprocket
- Checking the Brake Disc
- Installing the Driven Sprocket
- Installing the Rear Axle
- Front and Rear Brakes
- Front Brake Pads
- Rear Brake Pads
- Replacing the Front Brake Pads
- Replacing the Rear Brake Pads
- Front Brake Master Cylinder
- Rear Brake Master Cylinder
- Checking the Master Cylinders
- Assembling the Front Brake Master Cylinder
- Assembling the Rear Brake Master Cylinder
- Installing the Front Brake Master Cylinder
- Installing the Rear Brake Master Cylinder
- Front Brake Calipers
- Rear Brake Caliper
- Removing the Parking Brake Cable
- Disassembling the Front and Rear Brake Calipers
- Checking the Front and Rear Brake Calipers
- Assembling the Front Brake Calipers
- Assembling the Rear Brake Caliper
- Installing the Front Brake Calipers
- Installing the Rear Brake Caliper
- Steering System
- Handlebar
- Removing the Front Brake Light Switch and Clutch Switch
- Removing the Handlebar Grips
- Checking the Handlebar
- Installing the Handlebar
- Installing the Handlebar Grips
- Installing the Clutch Lever
- Installing the Brake Master Cylinder
- Steering Stem
- Removing the Bearing Retainer
- Checking the Steering Stem
- Installing the Bearing Retainer
- Installing the Steering Stem
- Installing the Lock Washer
- Installing the Pitman Arm
- Tie-Rods and Steering Knuckles
- Removing the Steering Knuckles
- Checking the Tie-Rods
- Checking the Steering Knuckles
- Installing the Tie-Rods
- Front Arms and Front Shock Absorber Assemblies
- Removing the Front Arms
- Checking the Front Arms
- Handling the Front Shock Absorber and Gas Cylinder
- Disposing of a Front Shock Absorber and Gas Cylinder
- Checking the Front Shock Absorbers
- Checking the Ball Joints
- Installing the Front Arms
- Rear Shock Absorber and Relay Arm
- Handling the Rear Shock Absorber and Gas Cylinder
- Disposing of a Rear Shock Absorber and Gas Cylinder
- Removing the Rear Shock Absorber
- Checking the Rear Shock Absorber
- Checking the Relay Arm and Connecting Arm
- Installing the Relay Arm and Connecting Arm
- Installing the Rear Shock Absorber
- Swingarm and Drive Chain
- Removing the Swingarm
- Checking the Swingarm
- Checking the Drive Chain
- Installing the Swingarm
- Installing the Drive Sprocket
ELECTRICAL
- Electrical Components
- Checking Switch Continuity
- Checking the Switches
- Checking the Bulbs and Bulb Sockets
- Types of Bulbs
- Checking the Condition of the Bulbs
- Checking the Condition of the Bulb Sockets
- Ignition System
- Circuit Diagram
- Throttle Override System (T.O.R.S.) Operation
- Troubleshooting
- Checking the Throttle Override System
- Electric Starting System
- Circuit Diagram
- Starting Circuit Cut-Off System Operation
- Troubleshooting
- Starter Motor
- Checking the Starter Motor
- Assembling the Starter Motor
- Charging System
- Circuit Diagram
- Troubleshooting
- Lighting System
- Circuit Diagram
- Troubleshooting
- Checking the Lighting System
- Signal System
- Circuit Diagram
- Troubleshooting
- Checking the Signaling System
- Cooling System
- Circuit Diagram
- Troubleshooting
TROUBLESHOOTING
- Starting Failure/Hard Starting
- Fuel System
- Electrical System
- Compression System
- Poor Idle Speed Performance
- Poor Idle Speed Performance
- Poor Medium and High-Speed Performance
- Poor Medium and High-Speed Performance
- Faulty Gear Shifting
- Hard Shifting
- Shift Pedal Does Not Move
- Jumps Out Gear
- Clutch Slipping/Dragging
- Clutch Slipping
- Clutch Dragging
- Overheating
- Overheating
- Faulty Brake
- Poor Braking Effect
- Shock Absorber Malfunction
- Malfunction
- Unstable Handling
- Unstable Handling
- Lighting System
- Headlight Does Not Come On
- Tail/Brake Light Does Not Light
- Bulb Burnt Out
- Tail/Brake Light Bulb Burnt Out
GENERAL INFORMATION
- Description
- Machine Identification
- Important Information
- Checking of Connection
- Special Tools
- Control Functions
- Fuel
- Starting and Break-In
- Torque-Check Points
- Cleaning and Storage
SPECIFICATIONS
- General Specifications
- Maintenance Specifications
- General Torque Specifications
- Definition of Units
- Lubrication Diagrams
- Cable Routing Diagram
REGULAR INSPECTION AND ADJUSTMENTS
- Maintenance Intervals
- Pre-Operation Inspection and Maintenance
- Engine
- Chassis
- Electrical
ENGINE
- Seat, Fuel Tank, and Side Covers
- Exhaust Pipe and Silencer
- Radiator
- Carburetor
- Camshafts
- Cylinder Head
- Valves and Valve Springs
- Cylinder and Piston
- Clutch
- Oil Filter, Water Pump, and Crankcase Cover (Right)
- Balancer
- Oil Pump
- Kick Axle and Shift Shaft
- CDI Magneto
- Engine Removal
- Crankcase and Crankshaft
- Transmission, Shift Cam, and Shift Fork
CHASSIS
- Front Wheel and Rear Wheel
- Front Brake and Rear Brake
- Front Fork
- Handlebar
- Steering
- Swingarm
- Rear Shock Absorber
ELECTRICAL
- Electrical Components and Wiring Diagram
- Map-Controlled CDI Unit
- Ignition System
- TPS (Throttle Position Sensor) System
TUNING
- Engine
- Chassis
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