Yamaha YFZ450 Manual

This Clymer ATV manual covers the Yamaha YFZ450 for these years: 2004, 2005, 2006, 2007, 2008, 2009

Note: Does not cover the YFZ450R or YFZ450R SE models.

Clymer ATV repair manuals are the best reference book for repair and service information. The service manual is written for the do-it-yourselfer as well as the experienced mechanic, This repair manual is the cheapest way to keep your four wheeler running properly. This service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the Yamaha YFZ 450. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure.

The Yamaha YFZ 450 manual includes the following information:

Quick Reference Data

Chapter One/General Information
Manual Organization/Warnings, cautions and notes/Safety/Serial numbers and information labels/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage/Specifications

Chapter Two/Troubleshooting
Starting the engine/Engine spark test/Engine performance/Engine noise/Engine leakdown test/Clutch/External shift mechanism and transmission/Electrical testing/Engine starting system/Brakes/Steering and handling

Chapter Three/Lubrication and Maintenance
Pre-ride inspection/Engine oil/Air filter/Control cable inspection and lubrication/Throttle cable and speed limiter adjustment/Clutch lever/Brakes/Drive chain/Tires and wheels/Front wheel bearing inspection/Steering system/Front suspension/Rear suspension/Battery/Cooling system/Carburetor/Crankcase breather hoses/Spark plug/Ignition timing inspection/Compression test/Valve clearance adjustment/Exhaust system/Fastener inspection/Specification

Chapter Four/Engine Top End
Exhaust system/Cylinder head cover/Camshafts/Camshaft bearing clearance measurement/Cam chain tensioner/Cam chain and guide/Cylinder head/Valves/Cylinder/Piston and piston rings/Specifications

Chapter Five/Engine Lower End
Engine/Torque limiter/Left crankcase cover/Starter idler gear/Flywheel (alternator rotor) and starter clutch/Camshaft chain and guides/Right crankcase cover/Balancer and primary drive gears/Oil pump/Crankcase/Crankcase seal and bearing replacement/Crankshaft/Engine break-in/Specifications

Chapter Six/Clutch and External Shift Mechanism
Clutch cover/Clutch/Clutch release lever assembly/External shift mechanism/Clutch cable/Specifications

Chapter Seven/Transmission and Internal Gearshift Mechanism
Transmission service notes/Mainshaft/Countershaft/Transmission inspection/Shift drum and forks/Specifications

Chapter Eight/Fuel System and Emission Control
Carburetor/Float adjustment/Carburetor adjustment and rejetting/Air box/Fuel tank/Fuel valve/Throttle cable/Crankcase breather system/Specifications

Chapter Nine/Electrical System
Electrical component replacement/Continuity testing/Electrical connectors/Negative battery terminal/Battery/Charging system/Alternator/Ignition system/Starter/Starting circuit cutoff system/Starter relay/Lighting system/Cooling system/Throttle position sensor/Switches/Specifications

Chapter Ten/Cooling System
Cooling system service notes/Pressure test/Hoses and clamps/Radiator/Coolant reservoir/Radiator fan/Water pump housing/Water pump/Specifications

Chapter Eleven/Wheels, Tires and Drive Chain
Wheel/Tires/Sprockets/Drive chain/Specifications

Chapter Twelve/Front Suspension and Steering
Handlebar/Shock absorbers/Front wheel hub/Tie rod/Steering knuckle/Control arms/Steering shaft/Specifications

Chapter Thirteen/Rear Axle and Suspension
Wheel hub/Rear axle/Rear axle hub/Shock absorber/Shock linkage/Swing arm/Specifications

Chapter Fourteen/Brakes
Brake fluid selection/Brake service notes/Front brake pads/Front brake caliper/Front master cylinder/Rear brake pads/Rear brake caliper/Rear master cylinder/Rear brake pedal/Brake disc/Front brake hose-tube removal-installation/Rear brake hose removal-installation/Brake system draining/Brake bleeding/Specifications

Chapter Fifteen/Body
Seat/Fuel tank cover/Fuel tank shield/Side covers/Front fender/Rear fender/Foot protectors/Footrests/Engine skidplate/Specification

Index

Wiring Diagrams

The Yamaha YFZ450 manual contains the following:

• Handy thumb-tabs put the chapter you need right at your fingertips.
• Detailed substeps expand on service procedure information.
• Notes, cautions and warnings throughout each chapter pinpoint critical information.
• Numbered instructions guide you through every repair procedure step by step.
• Bold figure numbers help you quickly match illustrations with instructions.
• Detailed illustrations, drawings and photos guide you through every service procedure.
• Exploded views help you identify and examine parts in detail.
• Numbered table of contents . . . easy to use so that you can find the information you need fast.
• Clymer repair manuals also make it easy to diagnose and repair electrical system problems on your all terrain vehicle.
•  Troubleshooting and electrical service procedures are combined with detailed wiring diagrams (color on select titles) for ease of use.