This Yamaha YFZ450 Manual is 320 pages.
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 / Specifications
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 idle 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 SHIFT 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 rods / 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 / Specifications
SUPPLEMENT / 2009-ON YFZ450R
General information / Troubleshooting / Electronic diagnostic system / Lubrication and maintenance / Engine oil / Idle speed / Spark plug / Engine top end / Cylinder head / Piston and piston rings / Engine lower end / Torque limiter / Left crankcase cover / Starter idle gear / Clutch and external shift mechanism / Clutch / External shift mechanism / Transmission and internal gearshift mechanism / Transmission mainshaft / Transmission countershaft / Shift forks / Fuel injection system / System operation / Fuel delivery system tests / Fuel pump / Throttle body / Throttle position sensor (TPS) / Engine control unit (ECU) / Intake air pressure (IAP) sensor / Intake air temperature sensor / Coolant temperature sensor / Electrical system / Crankshaft position sensor / Ignition system / Ignition coil / Spark plug cap / Radiator fan thermoswitch / Fuel sending unit / Speed sensor / Fuel injection system fuse / Main (fuel system) relay / Lean angle sensor / Starter / Cooling system / Water pump / Wheel, tires and drive chain / Front suspension and steering / Handlebar holders / Steering shaft / Brakes / Rear brake master cylinder / Body
INDEX
COLOR WIRING DIAGRAMS
Models: YFZ450BB Bill Ballance Edition YFZ450SE Special Edition YFZ450SP2 Special Edition II 2 YFZ450 YFZ 450 BB SE SP2 SPII YFZ450R
Years: 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
YFZ 450 450SE 450SP2 450R SE SP2 R
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YFZ450 (2004-2013)
YFZ450BB Bill Ballance Edition (2006-2007)
YFZ450SE Special Edition (2005, 2007)
YFZ450SE2 Special Edition II (2007)
YFZ450SP Special Edition (2006, 2008)
YFZ450SP2 Special Edition II (2008)
YFZ450R (2004-2013)
Does not cover YFZ450X models.