2004-2009 Yamaha YFZ450 ATV OEM Service & Repair Manual

LIT-11616-17-11 5TG-28197-10 YFZ450S SERVICE MANUAL

EBS00002 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair. Repairs attempted by anyone without this knowledge are likely to render the machine unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig- nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: _ Designs and specifications are subject to change without notice. EBS00003 IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander or a person checking or repairing the machine. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. A NOTE provides key information to make procedures easier or clearer. WARNING CAUTION: NOTE:

EBS00004 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa- nied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs. 2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 6. The meanings of the symbol marks are given on the next page. 4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition to the exploded diagram and the job instruction chart.

EBS00006 SYMBOLS The following symbols are not relevant to every machine. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor 7 Chassis 8 Electrical 9 Troubleshooting Symbols 0 to G indicate the following 0 Serviceable with engine mounted A Filling fluid B Lubricant C Special tool D Torque E Wear limit, clearance F Engine speed G Electrical data (Ω, V, A) Symbols H to N in the exploded diagrams indicate the types of lubricants and lubrication points. H Apply engine oil I Apply gear oil J Apply molybdenum disulfide oil K Apply wheel bearing grease L Apply lithium-soap-based grease M Apply molybdenum disulfide grease Symbols N to O in the exploded diagrams indicate where to apply a locking agent N and when to install a new part O. N Apply the locking agent (LOCTITE ® ) O Replace 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O GEN INFO SPEC CHK ADJ ENG COOL CARB CHAS – + ELEC TRBL SHTG T R . . E G M B LS M LT New

EBS00008 TABLE OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 ENGINE ENG 4 COOLING SYSTEM COOL 5 CARBURETOR CARB 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING TRBL SHTG 9 – +

CHAPTER 1 GENERAL INFORMATION MACHINE IDENTIFICATION........................................................................... 1-1 VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1 MODEL LABEL.......................................................................................... 1-1 IMPORTANT INFORMATION ......................................................................... 1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2 REPLACEMENT PARTS........................................................................... 1-2 GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2 LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-3 BEARINGS AND OIL SEALS .................................................................... 1-3 CIRCLIPS .................................................................................................. 1-3 CHECKING THE CONNECTIONS ............................................................ 1-4 SPECIAL TOOLS ............................................................................................ 1-5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................ 2-4 CHASSIS SPECIFICATIONS ........................................................................ 2-12 ELECTRICAL SPECIFICATIONS ................................................................. 2-14 TIGHTENING TORQUES .............................................................................. 2-16 ENGINE TIGHTENING TORQUES ........................................................ 2-16 CHASSIS TIGHTENING TORQUES ...................................................... 2-19 HOW TO USE THE CONVERSION TABLE.................................................. 2-21 GENERAL TIGHTENING TORQUE SPECIFICATIONS ............................... 2-21 LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-22 ENGINE ................................................................................................... 2-22 COOLANT FLOW DIAGRAMS ..................................................................... 2-24 OIL FLOW DIAGRAMS ................................................................................. 2-26 CABLE ROUTING ......................................................................................... 2-28

CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION.............................................................................................. 3-1 PERIODIC MAINTENANCE/LUBRICATION .................................................. 3-1 SEAT, FENDERS AND FUEL TANK .............................................................. 3-3 SEAT, FUEL TANK COVER AND SIDE COVERS ................................... 3-3 FOOT PROTECTORS AND ENGINE SKID PLATE ................................. 3-4 HEADLIGHTS AND FRONT FENDER ...................................................... 3-5 REAR FENDER ......................................................................................... 3-6 FUEL TANK ............................................................................................... 3-7 ENGINE ........................................................................................................... 3-8 ADJUSTING THE VALVE CLEARANCE .................................................. 3-8 ADJUSTING THE ENGINE IDLING SPEED ........................................... 3-13 ADJUSTING THE THROTTLE LEVER FREE PLAY .............................. 3-14 ADJUSTING THE SPEED LIMITER........................................................ 3-16 CHECKING THE SPARK PLUG ............................................................. 3-17 CHECKING THE IGNITION TIMING ....................................................... 3-18 CHECKING THE ENGINE OIL LEVEL.................................................... 3-19 CHANGING THE ENGINE OIL ............................................................... 3-21 ADJUSTING THE CLUTCH CABLE........................................................ 3-24 CLEANING THE AIR FILTER ELEMENT................................................ 3-26 CHECKING THE COOLANT LEVEL ....................................................... 3-28 CHANGING THE COOLANT................................................................... 3-28 CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ......... 3-32 CLEANING THE SPARK ARRESTER .................................................... 3-33 CHASSIS ....................................................................................................... 3-34 ADJUSTING THE FRONT BRAKE ......................................................... 3-34 ADJUSTING THE BRAKE LEVER .......................................................... 3-34 ADJUSTING THE REAR BRAKE ............................................................ 3-34 ADJUSTING THE PARKING BRAKE...................................................... 3-35 CHECKING THE BRAKE FLUID LEVEL................................................. 3-36 CHECKING THE FRONT BRAKE PADS ................................................ 3-37 CHECKING THE REAR BRAKE PADS .................................................. 3-38 ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................. 3-39 CHECKING THE BRAKE HOSES........................................................... 3-39 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-40 ADJUSTING THE SHIFT PEDAL ............................................................ 3-42 ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-43 CHECKING THE STEERING SYSTEM .................................................. 3-44 ADJUSTING THE TOE-IN ....................................................................... 3-45 CHECKING THE FRONT AND REAR SHOCK ABSORBERS ............... 3-46 ADJUSTING THE FRONT SHOCK ABSORBERS ................................. 3-47 ADJUSTING THE REAR SHOCK ABSORBER ...................................... 3-49 CHECKING THE TIRES .......................................................................... 3-53

CHECKING THE WHEELS ..................................................................... 3-55 CHECKING AND LUBRICATING THE CABLES .................................... 3-55 LUBRICATING THE LEVERS AND PEDALS ......................................... 3-56 ELECTRICAL SYSTEM................................................................................. 3-57 CHECKING AND CHARGING THE BATTERY ....................................... 3-57 CHECKING THE FUSES ........................................................................ 3-64 ADJUSTING THE HEADLIGHT BEAM ................................................... 3-65 REPLACING A HEADLIGHT BULB ........................................................ 3-66 CHAPTER 4 ENGINE ENGINE REMOVAL ........................................................................................ 4-1 MUFFLER AND EXHAUST PIPE .............................................................. 4-1 INSTALLING THE EXHAUST PIPE AND MUFFLER................................ 4-2 LEADS, CABLES AND HOSES ................................................................ 4-4 ENGINE MOUNTING BOLTS ................................................................... 4-6 INSTALLING THE ENGINE....................................................................... 4-8 CAMSHAFTS................................................................................................... 4-9 CYLINDER HEAD COVER........................................................................ 4-9 CAMSHAFTS .......................................................................................... 4-10 REMOVING THE CAMSHAFTS.............................................................. 4-11 CHECKING THE CAMSHAFTS .............................................................. 4-12 CHECKING THE CAMSHAFT SPROCKETS ......................................... 4-14 CHECKING THE DECOMPRESSION SYSTEM..................................... 4-14 CHECKING THE TIMING CHAIN GUIDE ............................................... 4-14 CHECKING THE TIMING CHAIN TENSIONER...................................... 4-15 INSTALLING THE CAMSHAFTS ............................................................ 4-15 CYLINDER HEAD.......................................................................................... 4-18 REMOVING THE CYLINDER HEAD....................................................... 4-20 CHECKING THE CYLINDER HEAD ....................................................... 4-20 CHECKING THE OIL DELIVERY PIPE................................................... 4-21 CHECKING THE TIMING CHAIN GUIDE ............................................... 4-21 INSTALLING THE CYLINDER HEAD ..................................................... 4-21 VALVES AND VALVE SPRINGS .................................................................. 4-24 REMOVING THE VALVES AND VALVE SPRINGS ............................... 4-26 CHECKING THE VALVES AND VALVE SPRINGS ................................ 4-27 CHECKING THE VALVE LIFTERS ......................................................... 4-32 INSTALLING THE VALVES AND VALVE SPRINGS .............................. 4-32

CYLINDER AND PISTON.............................................................................. 4-34 REMOVING THE PISTON ...................................................................... 4-35 CHECKING THE CYLINDER AND PISTON ........................................... 4-35 CHECKING THE PISTON RINGS........................................................... 4-37 CHECKING THE PISTON PIN ................................................................ 4-38 INSTALLING THE PISTON ..................................................................... 4-40 INSTALLING THE CYLINDER ................................................................ 4-41 A.C. MAGNETO............................................................................................. 4-42 REMOVING THE A.C. MAGNETO ROTOR............................................ 4-44 CHECKING THE STATOR COIL AND PICKUP COIL ............................ 4-44 CHECKING THE STARTER CLUTCH .................................................... 4-45 CHECKING THE TORQUE LIMITER ...................................................... 4-46 INSTALLING THE A.C. MAGNETO ROTOR .......................................... 4-46 CLUTCH ........................................................................................................ 4-48 REMOVING THE CLUTCH ..................................................................... 4-50 CHECKING THE FRICTION PLATES..................................................... 4-50 CHECKING THE CLUTCH PLATES ....................................................... 4-51 CHECKING THE CLUTCH SPRINGS..................................................... 4-51 CHECKING THE CLUTCH HOUSING .................................................... 4-51 CHECKING THE CLUTCH BOSS ........................................................... 4-52 CHECKING THE PRESSURE PLATE .................................................... 4-52 CHECKING THE PUSH RODS ............................................................... 4-52 CHECKING THE PUSH LEVER.............................................................. 4-52 CHECKING THE PRIMARY DRIVEN GEAR .......................................... 4-52 INSTALLING THE CLUTCH .................................................................... 4-53 BALANCER ................................................................................................... 4-55 REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR .......................................................... 4-56 CHECKING THE PRIMARY DRIVE GEAR, BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR .......................................................... 4-56 CHECKING THE BALANCER ................................................................. 4-56 INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR .......................................................... 4-57 OIL PUMP...................................................................................................... 4-58 CHECKING THE OIL PUMP ................................................................... 4-60 SHIFT SHAFT ................................................................................................ 4-61 CHECKING THE SHIFT SHAFT ............................................................. 4-63 CHECKING THE STOPPER LEVER ...................................................... 4-63 CHECKING THE SHIFT GUIDE AND SHIFT LEVER ............................. 4-63 CHECKING THE SHIFT DRUM SEGMENT ........................................... 4-63 INSTALLING THE SHIFT LEVER ........................................................... 4-63 INSTALLING THE SHIFT SHAFT ........................................................... 4-64

CRANKCASE ................................................................................................ 4-65 OIL SEAL AND BEARING ....................................................................... 4-67 SEPARATING THE CRANKCASE .......................................................... 4-68 CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 2 ............. 4-68 CHECKING THE TIMING CHAIN AND GUIDE....................................... 4-69 CHECKING THE BEARINGS AND OIL SEALS ...................................... 4-69 CHECKING THE CRANKCASE .............................................................. 4-69 ASSEMBLING THE CRANKCASE.......................................................... 4-70 CRANKSHAFT .............................................................................................. 4-72 REMOVING THE CRANKSHAFT ........................................................... 4-73 CHECKING THE CRANKSHAFT ............................................................ 4-73 INSTALLING THE CRANKSHAFT .......................................................... 4-74 TRANSMISSION............................................................................................ 4-75 MAIN AXLE ............................................................................................. 4-76 DRIVE AXLE ........................................................................................... 4-77 CHECKING THE SHIFT FORKS............................................................. 4-78 CHECKING THE SHIFT DRUM .............................................................. 4-78 CHECKING THE TRANSMISSION ......................................................... 4-78 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .............................. 4-79 INSTALLING THE TRANSMISSION ....................................................... 4-80 CHAPTER 5 COOLING SYSTEM RADIATOR ...................................................................................................... 5-1 CHECKING THE RADIATOR .................................................................... 5-3 INSTALLING THE RADIATOR .................................................................. 5-4 WATER PUMP................................................................................................. 5-5 CHECKING THE WATER PUMP .............................................................. 5-7 CHAPTER 6 CARBURETOR CARBURETOR................................................................................................ 6-1 DISASSEMBLING THE CARBURETOR ................................................... 6-5 CHECKING THE CARBURETOR ............................................................. 6-5 ASSEMBLING THE CARBURETOR ......................................................... 6-7 ADJUSTING THE ACCELERATOR PUMP TIMING ................................. 6-8 INSTALLING THE CARBURETOR JOINT ................................................ 6-8 INSTALLING THE CARBURETOR ........................................................... 6-9 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ... 6-9

2004-2009 Yamaha YFZ450 ATV OEM Service & Repair Manual

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