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Yamaha YFZ450S 2003 User Manual

Yamaha YFZ450S 2003
375 pages
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YFZ450S
5TG2-AE1
SERVICE MANUAL

Table of Contents

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Yamaha YFZ450S 2003 Specifications

General IconGeneral
BrandYamaha
ModelYFZ450S 2003
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information

How to Use This Manual

Provides instructions on the manual's organization, including chapter titles, section titles, and sub-section procedures.

Symbols Reference

Explains symbols used in the manual to indicate chapter subjects, specific service items, lubricants, and tools.

Special Tools

Lists and illustrates special tools required for tune-up and assembly, with part numbers for ordering.

Specifications

General Specifications

Details overall dimensions, weight, engine type, displacement, bore, stroke, compression ratio, starting system, and lubrication system.

Engine Specifications

Provides specific measurements and limits for engine components like cylinder head, camshaft, piston, rings, and crankshaft.

Chassis Specifications

Lists specifications for steering system, suspension, wheels, drive chain, brakes, and frame geometry.

Tightening Torques

Specifies torque values for engine and chassis fasteners to ensure proper assembly and prevent damage.

Lubrication Points and Lubricant Types

Identifies lubrication points for engine components and specifies the type of lubricant to be used for each.

Periodic Checks and Adjustments

Periodic Maintenance and Lubrication Schedule

Outlines a maintenance schedule detailing checks and lubrication intervals for various machine components.

Engine Checks and Adjustments

Covers procedures for adjusting valve clearance, engine idling speed, throttle lever, and checking spark plug and oil level.

Chassis Checks and Adjustments

Details checks and adjustments for brakes, chain slack, steering system, tires, and suspension components.

Battery Check and Charging

Explains how to check the battery's condition and perform charging procedures safely and effectively.

Tire Checks

Provides guidance on checking tire pressure, wear, and characteristics to ensure safe handling.

Engine

Engine Removal Procedures

Details the steps for removing the engine, including muffler, exhaust pipe, and related components.

Camshaft Service

Covers removal, checking, and installation of camshafts, sprockets, and related timing components.

Cylinder Head Service

Provides instructions for removing, checking, and installing the cylinder head, gasket, and timing chain guide.

Valves and Valve Springs Service

Explains procedures for removing, checking, and installing valves, springs, lifters, and seats.

Cylinder and Piston Service

Details the process for removing, checking, and installing the cylinder, piston, rings, and pin.

Clutch Service

Covers removal, checking of plates, springs, housing, and installation of the clutch assembly.

Crankshaft Service

Provides instructions for removing, checking, and installing the crankshaft, including side clearance and runout.

Cooling System

Radiator Service

Details radiator removal, checking of fins and hoses, and radiator cap pressure testing.

Water Pump Service

Covers water pump removal and checking of housing, impeller, shaft, seals, and bearings.

Carburetor

Carburetor Components and Disassembly

Details carburetor removal and disassembly, including identification of components and basic checks.

Throttle Position Sensor Check and Adjustment

Explains how to check and adjust the throttle position sensor's voltage output for proper engine operation.

Chassis

Front and Rear Wheels Service

Covers removal, checking, and installation of front and rear wheels, hubs, and brake discs.

Rear Axle and Hub Service

Details procedures for removing, checking, and installing the rear axle, hub, and driven sprocket.

Front and Rear Brakes Service

Covers replacement of brake pads, master cylinder, calipers, and bleeding the brake system.

Steering System Service

Includes handlebar, steering stem, tie-rods, and knuckle checks and installation procedures.

Front Arms and Shock Absorber Assemblies

Details removal, checking, and installation of front arms, ball joints, and shock absorbers.

Swingarm and Drive Chain Service

Covers removal, checking, cleaning, and installation of the swingarm, drive chain, and sprockets.

Electrical System

Electrical Components Overview

Provides a diagram illustrating the location of major electrical components and their corresponding numbers.

Switch Continuity Checks

Explains how to check switch continuity using a pocket tester, including proper probe placement.

Ignition System Troubleshooting

Guides users through diagnosing and resolving issues within the ignition system, including spark and timing.

Electric Starting System Troubleshooting

Provides steps to diagnose and resolve problems with the starting motor, relay, and associated circuits.

Starter Motor Service

Covers starter motor removal, disassembly, checking, and assembly procedures.

Charging System Troubleshooting

Guides users through diagnosing charging system faults, including battery, coils, and rectifier/regulator.

Lighting System Troubleshooting

Details troubleshooting steps for headlight, tail/brake lights, and other lighting system components.

Signal System Troubleshooting

Provides diagnostic procedures for signaling system failures, including indicators and warning lights.

Cooling System Electrical Checks

Focuses on troubleshooting electrical aspects of the cooling system, such as the fan motor and thermo switches.

Troubleshooting

Starting Failure and Hard Starting

Lists potential causes and troubleshooting steps for engine starting issues related to fuel, electrical, and compression systems.

Poor Idle Speed Performance

Addresses issues related to unstable or incorrect engine idle speed, often caused by carburetor or electrical faults.

Faulty Gear Shifting and Clutch Issues

Covers problems with gear shifting, clutch slipping, and dragging, including related transmission components.

Overheating and Faulty Brake Diagnosis

Addresses engine overheating causes and symptoms of poor braking performance.

Unstable Handling and Lighting System Issues

Covers causes of unstable vehicle handling and troubleshooting for lighting system failures.

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