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Yamaha YFZ450S ATV Service Manual

Yamaha YFZ450S (designated as 5TG1) is powered by 439cc 4 shot DOHC liquifiable cooled engine teamed with a 5 movement practice transmittal, wet tenfold disc accumulation typewrite. This recitation is an all in one drill, covers personnel /repair recitation and galvanic wiring plot profitable for those who own Yamaha YZF-450S and requisite to repair/ aid the ATV

Contents:

• GENERAL INFORMATION
  • MACHINE IDENTIFICATION [ VEHICLE IDENTIFICATION NUMBER ~ MODEL LABEL ]
  • IMPORTANT INFORMATION [ PREPARATION FOR REMOVAL AND DISASSEMBLY ~ REPLACEMENT PARTS ~ GASKETS, OIL SEALS AND O-RINGS ~ LOCK WASHERS/PLATES AND COTTER PINS ~ BEARINGS AND OIL SEALS ~ CIRCLIPS ~ CHECKING THE CONNECTIONS ]
  • SPECIAL TOOLS
• SPECIFICATIONS
  • GENERAL SPECIFICATIONS
  • ENGINE SPECIFICATIONS
  • CHASSIS SPECIFICATIONS
  • ELECTRICAL SPECIFICATIONS
  • TIGHTENING TORQUES [ ENGINE TIGHTENING TORQUES ~ CHASSIS TIGHTENING TORQUES ]
  • HOW TO USE THE CONVERSION TABLE
  • GENERAL TIGHTENING TORQUE SPECIFICATIONS
  • LUBRICATION POINTS AND LUBRICANT TYPES [ ENGINE ]
  • COOLANT FLOW DIAGRAMS
  • OIL FLOW DIAGRAMS
  • CABLE ROUTING
• PERIODIC CHECKS AND ADJUSTMENTS
  • INTRODUCTION
  • PERIODIC MAINTENANCE/LUBRICATION [ SEAT, FENDERS AND FUEL TANK ~ SEAT, FUEL TANK COVER AND SIDE COVERS ~ FOOT PROTECTORS AND ENGINE SKID PLATE ~ HEADLIGHTS AND FRONT FENDER ~ REAR FENDER ~ FUEL TANK ]
  • ENGINE [ ADJUSTING THE VALVE CLEARANCE ~ ADJUSTING THE ENGINE IDLING SPEED ~ ADJUSTING THE THROTTLE LEVER FREE PLAY ~ ADJUSTING THE SPEED LIMITER ~ CHECKING THE SPARK PLUG ~ CHECKING THE IGNITION TIMING ~ CHECKING THE ENGINE OIL LEVEL ~ CHANGING THE ENGINE OIL ~ ADJUSTING THE CLUTCH CABLE ~ CLEANING THE AIR FILTER ELEMENT ~ CHECKING THE COOLANT LEVEL ~ CHANGING THE COOLANT ~ CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ~ CLEANING THE SPARK ARRESTER ]
  • CHASSIS [ ADJUSTING THE FRONT BRAKE ~ ADJUSTING THE BRAKE LEVER ~ ADJUSTING THE REAR BRAKE ~ ADJUSTING THE PARKING BRAKE ~ CHECKING THE BRAKE FLUID LEVEL ~ CHECKING THE FRONT BRAKE PADS ~ CHECKING THE REAR BRAKE PADS ~ ADJUSTING THE REAR BRAKE LIGHT SWITCH ~ CHECKING THE BRAKE HOSES ~ BLEEDING THE HYDRAULIC BRAKE SYSTEM ~ ADJUSTING THE SHIFT PEDAL ~ ADJUSTING THE DRIVE CHAIN SLACK ~ CHECKING THE STEERING SYSTEM ~ ADJUSTING THE TOE-IN ~ CHECKING THE FRONT AND REAR SHOCK ABSORBERS ~ ADJUSTING THE FRONT SHOCK ABSORBERS ~ ADJUSTING THE REAR SHOCK ABSORBER ~ CHECKING THE TIRES ~ CHECKING THE WHEELS ~ CHECKING AND LUBRICATING THE CABLES ~ LUBRICATING THE LEVERS AND PEDALS ]
  • ELECTRICAL SYSTEM [ CHECKING AND CHARGING THE BATTERY ~ CHECKING THE FUSES ~ ADJUSTING THE HEADLIGHT BEAM ~ REPLACING A HEADLIGHT BULB ]
• ENGINE
  • ENGINE REMOVAL [ MUFFLER AND EXHAUST PIPE ~ INSTALLING THE EXHAUST PIPE AND MUFFLER ~ LEADS, CABLES AND HOSES ~ ENGINE MOUNTING BOLTS ~ INSTALLING THE ENGINE ]
  • CAMSHAFTS [ CYLINDER HEAD COVER ~ CAMSHAFTS ~ REMOVING THE CAMSHAFTS ~ CHECKING THE CAMSHAFTS ~ CHECKING THE CAMSHAFT SPROCKETS ~ CHECKING THE DECOMPRESSION SYSTEM ~ CHECKING THE TIMING CHAIN GUIDE ~ CHECKING THE TIMING CHAIN TENSIONER ~ INSTALLING THE CAMSHAFTS ]
  • CYLINDER HEAD [ REMOVING THE CYLINDER HEAD ~ CHECKING THE CYLINDER HEAD ~ CHECKING THE OIL DELIVERY PIPE ~ CHECKING THE TIMING CHAIN GUIDE ~ INSTALLING THE CYLINDER HEAD ]
  • VALVES AND VALVE SPRINGS [ REMOVING THE VALVES AND VALVE SPRINGS ~ CHECKING THE VALVES AND VALVE SPRINGS ~ CHECKING THE VALVE LIFTERS ~ INSTALLING THE VALVES AND VALVE SPRINGS ]
  • CYLINDER AND PISTON [ REMOVING THE PISTON ~ CHECKING THE CYLINDER AND PISTON ~ CHECKING THE PISTON RINGS ~ CHECKING THE PISTON PIN ~ INSTALLING THE PISTON ~ INSTALLING THE CYLINDER ]
  • AC MAGNETO [ REMOVING THE AC MAGNETO ROTOR ~ CHECKING THE STATOR COIL AND PICKUP COIL ~ CHECKING THE STARTER CLUTCH ~ CHECKING THE TORQUE LIMITER ~ INSTALLING THE AC MAGNETO ROTOR ]
  • CLUTCH [ REMOVING THE CLUTCH ~ CHECKING THE FRICTION PLATES ~ CHECKING THE CLUTCH PLATES ~ CHECKING THE CLUTCH SPRINGS ~ CHECKING THE CLUTCH HOUSING ~ CHECKING THE CLUTCH BOSS ~ CHECKING THE PRESSURE PLATE ~ CHECKING THE PUSH RODS ~ CHECKING THE PUSH LEVER ~ CHECKING THE PRIMARY DRIVEN GEAR ~ INSTALLING THE CLUTCH ]
  • BALANCER [ REMOVING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR ~ CHECKING THE PRIMARY DRIVE GEAR, BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR ~ CHECKING THE BALANCER ~ INSTALLING THE BALANCER DRIVE GEAR AND BALANCER DRIVEN GEAR ]
  • OIL PUMP [ CHECKING THE OIL PUMP ]
  • SHIFT SHAFT [ CHECKING THE SHIFT SHAFT ~ CHECKING THE STOPPER LEVER ~ CHECKING THE SHIFT GUIDE AND SHIFT LEVER ~ CHECKING THE SHIFT DRUM SEGMENT ~ INSTALLING THE SHIFT LEVER ~ INSTALLING THE SHIFT SHAFT ]
  • CRANKCASE [ OIL SEAL AND BEARING ~ SEPARATING THE CRANKCASE ~ CHECKING THE OIL STRAINER AND OIL DELIVERY PIPE 2 ~ CHECKING THE TIMING CHAIN AND GUIDE ~ CHECKING THE BEARINGS AND OIL SEALS ~ CHECKING THE CRANKCASE ~ ASSEMBLING THE CRANKCASE ]
  • CRANKSHAFT [ REMOVING THE CRANKSHAFT ~ CHECKING THE CRANKSHAFT ~ INSTALLING THE CRANKSHAFT ]
  • TRANSMISSION [ MAIN AXLE ~ DRIVE AXLE ~ CHECKING THE SHIFT FORKS ~ CHECKING THE SHIFT DRUM ~ CHECKING THE TRANSMISSION ~ ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ~ INSTALLING THE TRANSMISSION ]
• COOLING SYSTEM
  • RADIATOR [ CHECKING THE RADIATOR ~ INSTALLING THE RADIATOR ]
  • WATER PUMP [ CHECKING THE WATER PUMP ]
• CARBURETOR
  • CARBURETOR [ DISASSEMBLING THE CARBURETOR ~ CHECKING THE CARBURETOR ~ ASSEMBLING THE CARBURETOR ~ ADJUSTING THE ACCELERATOR PUMP TIMING ~ INSTALLING THE CARBURETOR JOINT ~ INSTALLING THE CARBURETOR ~ CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ]
• CHASSIS
  • FRONT AND REAR WHEELS [ FRONT WHEELS ~ REAR WHEELS ~ CHECKING THE WHEELS ~ CHECKING THE WHEEL HUBS ~ CHECKING THE BRAKE DISCS ~ INSTALLING THE FRONT WHEEL HUB BEARINGS ~ INSTALLING THE FRONT BRAKE DISCS ~ INSTALLING THE FRONT WHEELS ~ INSTALLING THE WHEEL HUBS ]
  • REAR AXLE AND REAR AXLE HUB [ REMOVING THE REAR AXLE ~ CHECKING THE REAR AXLE ~ CHECKING THE DRIVEN SPROCKET ~ CHECKING THE BRAKE DISC ~ INSTALLING THE DRIVEN SPROCKET ~ INSTALLING THE REAR AXLE ]
  • FRONT AND REAR BRAKES [ FRONT BRAKE PADS ~ REAR BRAKE PADS ~ REPLACING THE FRONT BRAKE PADS ~ REPLACING THE REAR BRAKE PADS ~ FRONT BRAKE MASTER CYLINDER ~ REAR BRAKE MASTER CYLINDER ~ CHECKING THE MASTER CYLINDERS ~ ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ~ ASSEMBLING THE REAR BRAKE MASTER CYLINDER ~ INSTALLING THE FRONT BRAKE MASTER CYLINDER ~ INSTALLING THE REAR BRAKE MASTER CYLINDER ~ FRONT BRAKE CALIPERS ~ REAR BRAKE CALIPER ~ REMOVING THE PARKING BRAKE CABLE ~ DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS ~ CHECKING THE FRONT AND REAR BRAKE CALIPERS ~ ASSEMBLING THE FRONT BRAKE CALIPERS ~ ASSEMBLING THE REAR BRAKE CALIPER ~ INSTALLING THE FRONT BRAKE CALIPERS ~ INSTALLING THE REAR BRAKE CALIPER ]
  • STEERING SYSTEM [ HANDLEBAR ~ REMOVING THE FRONT BRAKE LIGHT SWITCH ~ AND CLUTCH SWITCH ~ REMOVING THE HANDLEBAR GRIPS ~ CHECKING THE HANDLEBAR ~ INSTALLING THE HANDLEBAR ~ INSTALLING THE HANDLEBAR GRIPS ~ INSTALLING THE CLUTCH LEVER ~ INSTALLING THE BRAKE MASTER CYLINDER ~ STEERING STEM ~ REMOVING THE BEARING RETAINER ~ CHECKING THE STEERING STEM ~ INSTALLING THE BEARING RETAINER ~ INSTALLING THE STEERING STEM ~ INSTALLING THE LOCK WASHER ~ INSTALLING THE PITMAN ARM ~ TIE-RODS AND STEERING KNUCKLES ~ REMOVING THE STEERING KNUCKLES ~ CHECKING THE TIE-RODS ~ CHECKING THE STEERING KNUCKLES ~ INSTALLING THE TIE-RODS ]
  • FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES [ REMOVING THE FRONT ARMS ~ CHECKING THE FRONT ARMS ~ HANDLING THE FRONT SHOCK ABSORBER AND GAS CYLINDER ~ DISPOSING OF A FRONT SHOCK ABSORBER AND GAS CYLINDER ~ CHECKING THE FRONT SHOCK ABSORBERS ~ CHECKING THE BALL JOINTS ~ INSTALLING THE FRONT ARMS ]
  • REAR SHOCK ABSORBER AND RELAY ARM [ HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER ~ DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER ~ REMOVING THE REAR SHOCK ABSORBER ~ CHECKING THE REAR SHOCK ABSORBER ~ CHECKING THE RELAY ARM AND CONNECTING ARM ~ INSTALLING THE RELAY ARM AND CONNECTING ARM ~ INSTALLING THE REAR SHOCK ABSORBER ]
  • SWINGARM AND DRIVE CHAIN [ REMOVING THE SWINGARM ~ CHECKING THE SWINGARM ~ CHECKING THE DRIVE CHAIN ~ INSTALLING THE SWINGARM ~ INSTALLING THE DRIVE SPROCKET ]
• ELECTRICAL
  • ELECTRICAL COMPONENTS
  • CHECKING SWITCH CONTINUITY
  • CHECKING THE SWITCHES
  • CHECKING THE BULBS AND BULB SOCKETS [ TYPES OF BULBS ~ CHECKING THE CONDITION OF THE BULBS ~ CHECKING THE CONDITION OF THE BULB SOCKETS ]
  • IGNITION SYSTEM [ CIRCUIT DIAGRAM ~ THROTTLE OVERRIDE SYSTEM (TORS) OPERATION ~ TROUBLESHOOTING ~ CHECKING THE THROTTLE OVERRIDE SYSTEM ]
  • ELECTRIC STARTING SYSTEM [ CIRCUIT DIAGRAM ~ STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ~ TROUBLESHOOTING ]
  • STARTER MOTOR [ CHECKING THE STARTER MOTOR ~ ASSEMBLING THE STARTER MOTOR ]
  • CHARGING SYSTEM [ CIRCUIT DIAGRAM ~ TROUBLESHOOTING ]
  • LIGHTING SYSTEM [ CIRCUIT DIAGRAM ~ TROUBLESHOOTING ~ CHECKING THE LIGHTING SYSTEM ]
  • SIGNAL SYSTEM [ CIRCUIT DIAGRAM ~ TROUBLESHOOTING ~ CHECKING THE SIGNALING SYSTEM ]
  • COOLING SYSTEM [ CIRCUIT DIAGRAM ~ TROUBLESHOOTING ]
• TROUBLESHOOTING
  • STARTING FAILURE/HARD STARTING [ FUEL SYSTEM ~ ELECTRICAL SYSTEM ~ COMPRESSION SYSTEM ]
  • POOR IDLE SPEED PERFORMANCE [ POOR IDLE SPEED PERFORMANCE ]
  • POOR MEDIUM AND HIGH-SPEED PERFORMANCE [ POOR MEDIUM AND HIGH-SPEED PERFORMANCE ]
  • FAULTY GEAR SHIFTING [ HARD SHIFTING ~ SHIFT PEDAL DOES NOT MOVE ~ JUMPS OUT GEAR ]
  • CLUTCH SLIPPING/DRAGGING [ CLUTCH SLIPPING ~ CLUTCH DRAGGING ]
  • OVERHEATING [ OVERHEATING ]
  • FAULTY BRAKE [ POOR BRAKING EFFECT ]
  • SHOCK ABSORBER MALFUNCTION [ MALFUNCTION ]
  • UNSTABLE HANDLING [ UNSTABLE HANDLING ]
  • LIGHTING SYSTEM [ HEADLIGHT DOES NOT COME ON ~ TAIL/BRAKE LIGHT DOES NOT LIGHT ~ BULB BURNT OUT ~ TAIL/BRAKE LIGHT BULB BURNT OUT ]
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