2005 Yamaha YZ450FV / YZ450F Owner's Service Manual (P/N LIT-11626-19-73)

This Yamaha Owner's Service Manual covers operation, maintenance, repair, and tuning for the 2005 YZ450FV and the YZ450F market variants listed above. It is the first edition, September 2005, P/N LIT-11626-19-73, with cover identifier 2S2-28199-10.

• Engine repair: Engine removal, camshaft and cylinder-head service, valve-clearance adjustment, crankcase separation, crankshaft inspection, and balancer shaft assembly.

• Clutch and transmission: Wet-clutch disassembly, primary kick starter service, and inspection and reassembly of transmission gears, shift cam, and shift forks.

• Fuel and tuning: FCR MX39 carburetor teardown, float-height and accelerator-pump timing adjustments, leak jet tuning, and symptom-based carburetor setting charts.

• Lubrication and cooling: Dry sump lubrication diagrams, trochoid oil pump inspection, oil-filter service, water-pump repair, and cooling-system pressure tests.

• Chassis and suspension: Front fork teardown, brake caliper and master-cylinder service, brake bleeding, steering head bearing replacement, and link-type monocross suspension work.

• Electrical diagnosis: Full-system wiring and cable routing diagrams, map-controlled CDI and Throttle Position Sensor (TPS) troubleshooting, ignition coil resistance tests, and TPS replacement and adjustment.

Owners can use the operating and routine-maintenance sections; internal repairs are suited to mechanics with precision measuring equipment and the specified special tools.

Engine Inspection and Reassembly

Exploded assembly views and job instruction charts identify parts and removal scope. Cylinder-head warp limits, camshaft runout checks, valve pad selection tables, and component-specific torque data support inspection before reassembly.

Yamaha specifies a staged torque-and-angle procedure for the main cylinder-head bolts. The camshaft section warns that uneven cap-bolt tightening can damage the cylinder head, camshaft caps, and camshafts.

Crankshaft removal uses the listed crankcase separating tool, YU-A9642 / 90890-04152; the installation section identifies the corresponding installing tools.

FCR MX39 Carburetor Setup

The tuning section relates jet selection to throttle opening and atmospheric conditions, with main-jet, pilot-jet, jet-needle, and leak-jet part-number tables. Its symptom chart distinguishes mixture problems from restricted fuel passages, a dirty air filter, and accelerator-pump faults.

The pilot-screw setting is individual to each machine, and the printed position is an example.

CDI and TPS Diagnostics

The electrical specifications distinguish the 2S2-00 CDI unit for USA/Canada from the 2S2-10 unit for other markets. Ignition and TPS troubleshooting charts help isolate connector, switch, coil, or sensor faults before the CDI unit is considered for replacement.

The 3-D ignition-timing map explains the relationship between throttle position, engine speed, and ignition timing. It is an illustrative diagram rather than an actual calibration map.

Fork and Rear Shock Service

Fork service covers the damper assembly, base valve, seals, and air bleeding. Yamaha recommends dealer maintenance for the front fork.

Suspension setting charts distinguish European baseline settings and link rear spring preload to spring identification marks; titanium and steel spring options have separate parts tables.

Rear shock work covers removal, spring and bearing replacement, and adjustment. Yamaha expressly prohibits disassembly of the nitrogen-filled cylinder or reservoir; this section does not provide an internal damper rebuild procedure.

The rear shock bearing instructions also explain how greasing the upper bearing's outer race can wear its press-fit bore. Brake work and pressurized suspension components call for particular care; consult a qualified technician when a procedure exceeds your training or equipment.

A Preview of Valve Clearances and Cooling Capacity

These examples are a small selection from the engine and cooling specifications.

Cold valve clearance is 0.10–0.15 mm for the intake valves and 0.20–0.25 mm for the exhaust valves on the covered YZ450FV/YZ450F engine. The adjustment section pairs these specifications with valve pad selection tables.

Total coolant capacity is 0.99 L, including all coolant routes. The cooling section also distinguishes radiator-cap testing from pressure testing the complete system.

PDF Navigation and Page Breakdown

Text search and diagram detail: The technical chapters contain searchable text, with bookmarks for chapters and major service sections. The preliminary warning and warranty pages are not text-searchable. Small wire-color and connector labels are readable when enlarged.

One printable English-language PDF contains 308 pages: 292 chapter pages, 15 pages of original front matter, and one back cover. The front matter includes the cover, safety and warranty notices, introductory material, and contents; all are included in the total.