Yamaha YZ450F(V) 2005 Service Manual | Owner's Data (P/N 2S2-28199-80)

These three factory Yamaha Owner's Service Manuals cover the 2006 YZ450F(V), 2007 YZ450F(W), and 2009 YZ450F(Y). All three machines use a 449cc liquid-cooled DOHC single, Keihin FCR-MX carburetion, kick starting, dry-sump lubrication, and a five-speed transmission. Yamaha pairs operating and inspection material with sequential disassembly, repair, assembly, and testing procedures supported by exploded job charts. That depth makes the set best suited to experienced owners and repair technicians who have proper measuring equipment and access to the listed special tools.

• Exact model-code coverage: 2006 YZ450FV/YZ450F codes 2S21 and 2S25 for the USA and Canada, 2S22 for Europe, and 2S24/2S26 for Australia, New Zealand, and South Africa. The 2007 codes are 2S27, 2S28, and 2S2A for those regional groups; the 2009 codes are 34P1, 34P2, and 34P4.
• 1,490 PDF pages total: YZ450F(V), 650 pages, P/N 2S2-28199-80, first edition September 2005; YZ450F(W), 650 pages, P/N 2S2-28199-81, first edition July 2006; and 2009 YZ450F(Y), 190 pages, English-edition P/N 34P-28199-80-E0, first edition May 2008. The outer 2009 cover is marked 34P-28199-80. The V and W PDFs include English, French, and German sections; the Y PDF contains the English E0 edition behind a multilingual outer cover.
• Internal engine repair: Covers engine removal and top-end repair, including camshaft timing, cylinder-head disassembly, valve-guide work, and piston inspection. Lower-end coverage reaches the clutch, oil and water pumps, balancer, crankcase separation, crankshaft installation, transmission, shift cam, and shift forks.
• Fuel and tuning work: Details FCR-MX39 carburetor removal and disassembly, accelerator-pump and jetting circuits, TPS replacement and adjustment, symptom-based jet selection, atmospheric compensation, gearing changes, and track-condition engine setup.
• Chassis and brake repair: Includes wheel and bearing service, front and rear brake master-cylinder and caliper disassembly, hose and disc checks, pad replacement, hydraulic bleeding, steering-head work, swingarm service, and drive-chain adjustment.
• Suspension work: Provides front-fork removal, disassembly, seal replacement, base-valve and damper service, oil-level and air-bleeding work, plus rear-shock removal, bearing and spring service, preload setup, and symptom-based front/rear tuning charts.
• Electrical diagnosis: Supplies wiring diagrams, ignition-system fault isolation, spark, coil, and CDI-magneto tests, neutral-switch checks, and TPS resistance, input/output voltage, and adjustment procedures. The V and W editions also explain map-controlled three-dimensional CDI ignition.

Model-Specific Shop Data

Each edition carries its own torque tables, fluid capacities, maintenance intervals, valve-clearance and wear limits, carburetor baseline data, electrical test specifications, and suspension settings. V, W, and Y specifications should be matched to the correct model code rather than treated as interchangeable. This is a three-volume set for the listed models, not an uninterrupted 2006-2009 run; no separate 2008 manual is included.

The special-tool sections pair North American YM/YU numbers with 90890-series references. Representative examples include valve spring compressor YM-4019/90890-04019, crankcase separator YU-A9642/90890-04152, fork seal driver YM-A0948/90890-01502, and dynamic spark or ignition testers YM-34487/90890-06754. The 2009 list also specifies digital tachometer YU-39951-B/90890-06760.

Diagrams That Support Diagnosis

The reference graphics go beyond exploded assembly views. They include engine lubrication diagrams, cable-routing diagrams, the electrical-components and wiring diagram, ignition-system inspection flowcharts, TPS inspection charts, and the V/W three-dimensional ignition-timing map. Carburetor throttle-opening charts show which circuits affect each operating range, while suspension symptom charts connect track behavior with inspection and adjustment areas.

Repair Cautions and Limits

The manuals flag several easy ways to damage parts. Front-fork contamination can compromise the built-in piston-rod assembly, and a bent inner tube must be replaced rather than straightened because straightening can dangerously weaken it. During water-pump repair, careless impeller-shaft installation can damage the oil-seal lip or dislodge its spring. Rear-shock coverage stops short of internal nitrogen-unit disassembly; Yamaha restricts that unit because its separate reservoir is under high pressure. Secure the motorcycle before chassis work, and keep carburetor service away from ignition sources.