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Yamaha YFZ450 YFZ450S 2003 - 2009 Complete OFFICIAL Factory Service / Repair / Full Workshop Manual

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🏷️ Basic Information Identification Make: Yamaha Model: YFZ450 Model Variant: YFZ450S Model Years Covered: 2003, 2004, 2005, 2006, 2007, 2008, 2009 Codes Vin Decoder Note: Specific VIN decoding information not provided in product details, but manual covers specified model years. 👋 Introduction Market Position Segment: High-Performance Sport ATV Target Audience: Enthusiasts, racers, and DIY mechanics focused on performance and customization. Competitive Analysis Key Competitors: Honda TRX series, Suzuki LT-R series, Kawasaki KFX series. Key Features Manual Value Proposition: Provides comprehensive, official factory data for accurate diagnostics, maintenance, and repairs, enabling owners to maintain peak performance. Delivery Benefit: Instant download eliminates shipping delays and costs, providing immediate access to critical repair information. 📋 Manual Details Coverage Areas Coverage Scope: Complete OFFICIAL Factory Service / Repair / Full Workshop Manual Page Count Total Pages: 375 Manual Type Type: Service Manual, Repair Manual, Workshop Manual Language Primary Language: English Format Delivery Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Yes (Cylinder Head, Block, Pistons, Rings, Rods, Crankshaft, Valve train, Camshaft, Carburetor, Oil Pump, Oil Pan, Timing Gears, Valve Locks, Freeze Plugs) Fuel System: Yes (Carburetor Assembly, Fuel Pump, Fuel Filter, Fuel Injector, Fuel Screen, Fuel Pipe, Fuel Tank Cap, Fuel Filler Neck) Ignition System: Yes (Ignition, Spark Plugs, Spark Plug Wires, Ignition Coil, Ignition Relay) Cooling System: Yes (Radiator, Radiator Fan, Oil Radiator, Oil Cooling, Coolant Hose, Fan Shroud, AC Condenser) Exhaust System: Yes (Muffler, Downpipe, Cat, Catalytic Converter, Exhaust, Headers, Manifold, Exhaust Gasket) Clutch System: Yes (Clutch, Clutch Shoe, Clutch Case, Clutch Kit, Clutch Slave Cylinder, Clutch Master Cylinder, Clutch Lines, Pressure Plate, Flywheel) Transmission Drivetrain: Yes (Transfercase, Transfer Case, Transfer Plate, Axles, Axle Assembly, Axle Shafts, CV Boots) Brakes: Yes (Brakes, Change Brakes, Brake Pads, Brake Shoes, Rotor, Rotor Replacement, Brake Discs, Brake System) Suspension Steering: Yes (Suspension, Suspension System, Steering System, Shocks, Struts) Electrical System Wiring Harnesses: Yes (Engine Harness, Wiring Harness, Chassis Wire Harness, Main Wire Harness, Wiring Diagrams, Electrical Wiring) Sensors Controls: Yes (Sensors, Oil Sensor, Pressure Sensor, Oil Pressure Sensor, Oxygen Sensor, Door Jamb Switch) Lighting: Yes (Interior Lighting, Lights, HID, Projector, Headlight Replacement, Taillight Replacement, Bulb Replacement, Fogs, Foglight, Foglight Replacement, Third Brake Light, Driving Lights, Fog Lights, Interior Lights, Lighting, Tail Lights, Backup Lights, Turn Signal, Side Markers, Headlight Relay, Starter Relay, Ignition Relay) Starting Charging: Yes (Alternator, Alternator Pulley, Starter, Recoil Starter, Starter Replacement, Battery, Battery Replacement) Body Frame Exterior Panels: Yes (Air Deflector, Air Hose, Clutch Hose, Brake Hose, Air Seals, Fan Cover, Filter Cover, Filter Housing, Sleeve, Bumper, Front Bumper, Rear Bumper, Fender, Doors, Emblem, Fuel Cap, Fuel Door, Grilles, Front Grille, Hood, Mud Guards, Mud Flaps, Trim, Trim Replacement, Turn Signal) Interior Components: Yes (Dashboard, Dash Replacement, Air Bags, CD Player Replacement, Glovebox, Center Console, Console Replacement, Floor Mat, Cargo Liners, Consoles, Organizers, Leather, Steering Wheel, Shifter, Pedals, Hub Caps, Wheel Cover) Glass Wipers: Yes (Glass, Window, Windshield, Wiper Blade, Wiper Motor, Washer Pump) Procedures Included Maintenance: Yes (Oil Change, Transmission Change, Fluid Change, Air Filter Replacement, Fuel Filter Replacement, Brake Change, Tire Rotation) Repair: Yes (Complete engine rebuild, transmission overhaul, brake system repair, suspension and steering system service, electrical component replacement, body panel repair and replacement) Troubleshooting: Yes (Diagnostic procedures, fault finding, electrical system troubleshooting) Installation: Yes (Component installation, accessory fitting guidance implied by factory specifications) Technical Depth Depth: Comprehensive Factory Workshop Manual covering all aspects of repair and maintenance. Special Procedures: Yes (Machining, Balancing, Torque Specs, Torque Values, Alignment) 📊 Manual Specifications File Format Format: PDF Searchability: Keyword Searchable Zoom Functionality: Yes (Zoom In/Out) Printability: Yes (Printable) Print Quality Quality: Factory Quality Binding Type Binding: N/A (PDF Download) Paper Type Paper: N/A (PDF Download) ⚙️ Engine Specifications Primary Engine Configuration: Liquid-cooled, DOHC, 5-valve, Four-stroke Single Displacement: 449cc Bore X Stroke: 95.0 mm x 63.1 mm Compression Ratio: 11.2:1 (typical, may vary slightly by year) Performance Horsepower Est: Approx. 40-45 HP (stock, may vary) Torque Est: Approx. 30-33 lb-ft (stock, may vary) Fuel System Carburetor: Mikuni BSR33/1 (typical, may vary by year) Fuel Type: Unleaded gasoline, 87-91 octane recommended Lubrication Oil Capacity: Approx. 1.90 L (with filter change) Oil Type: Yamalube 4 (or equivalent) SAE 10W-30 API SG or higher Cooling System Type: Forced liquid cooling 🔧 Transmission Standard Type: 5-speed constant mesh with reverse Features Clutch Type: Wet multi-plate 📐 Dimensions Exterior Length: Approx. 1,845 mm (72.6 in) Width: Approx. 1,240 mm (48.8 in) Height: Approx. 1,055 mm (41.5 in) Weights Dry Weight: Approx. 179 kg (395 lbs) Fuel Capacity: Approx. 10 L (2.6 gal) 🛡️ Safety Features Ratings Crash Test Data: N/A (ATV, not subject to standard automotive crash testing) Active Features Braking System: Hydraulic disc brakes front and rear. Passive Features Hand Guards: Integrated hand guards for rider protection. 💡 Technology Features Infotainment Features: Basic instrumentation (speedometer, odometer, engine hour meter, neutral indicator). No advanced...
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Art.-Nr: 39425
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Yamaha YFZ450 YFZ450S 2003 - 2009 Complete OFFICIAL Factory Service / Repair / Full Workshop ManualYamaha YFZ450 YFZ450S 2003 - 2009 Complete OFFICIAL Factory Service / Repair / Full Workshop ManualYamaha YFZ450 YFZ450S 2003 - 2009 Complete OFFICIAL Factory Service / Repair / Full Workshop ManualYamaha YFZ450 YFZ450S 2003 - 2009 Complete OFFICIAL Factory Service / Repair / Full Workshop Manual
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
YFZ450
Model Variant:
YFZ450S
Model Years Covered:
2003, 2004, 2005, 2006, 2007, 2008, 2009
Codes
Vin Decoder Note:
Specific VIN decoding information not provided in product details, but manual covers specified model years.
👋 Introduction
Market Position
Segment:
High-Performance Sport ATV
Target Audience:
Enthusiasts, racers, and DIY mechanics focused on performance and customization.
Competitive Analysis
Key Competitors:
Honda TRX series, Suzuki LT-R series, Kawasaki KFX series.
Key Features
Manual Value Proposition:
Provides comprehensive, official factory data for accurate diagnostics, maintenance, and repairs, enabling owners to maintain peak performance.
Delivery Benefit:
Instant download eliminates shipping delays and costs, providing immediate access to critical repair information.
📋 Manual Details
Coverage Areas
Coverage Scope:
Complete OFFICIAL Factory Service / Repair / Full Workshop Manual
Page Count
Total Pages:
375
Manual Type
Type:
Service Manual, Repair Manual, Workshop Manual
Language
Primary Language:
English
Format
Delivery Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Yes (Cylinder Head, Block, Pistons, Rings, Rods, Crankshaft, Valve train, Camshaft, Carburetor, Oil Pump, Oil Pan, Timing Gears, Valve Locks, Freeze Plugs)
Fuel System:
Yes (Carburetor Assembly, Fuel Pump, Fuel Filter, Fuel Injector, Fuel Screen, Fuel Pipe, Fuel Tank Cap, Fuel Filler Neck)
Ignition System:
Yes (Ignition, Spark Plugs, Spark Plug Wires, Ignition Coil, Ignition Relay)
Cooling System:
Yes (Radiator, Radiator Fan, Oil Radiator, Oil Cooling, Coolant Hose, Fan Shroud, AC Condenser)
Exhaust System:
Yes (Muffler, Downpipe, Cat, Catalytic Converter, Exhaust, Headers, Manifold, Exhaust Gasket)
Clutch System:
Yes (Clutch, Clutch Shoe, Clutch Case, Clutch Kit, Clutch Slave Cylinder, Clutch Master Cylinder, Clutch Lines, Pressure Plate, Flywheel)
Transmission Drivetrain:
Yes (Transfercase, Transfer Case, Transfer Plate, Axles, Axle Assembly, Axle Shafts, CV Boots)
Brakes:
Yes (Brakes, Change Brakes, Brake Pads, Brake Shoes, Rotor, Rotor Replacement, Brake Discs, Brake System)
Suspension Steering:
Yes (Suspension, Suspension System, Steering System, Shocks, Struts)
Electrical System
Wiring Harnesses:
Yes (Engine Harness, Wiring Harness, Chassis Wire Harness, Main Wire Harness, Wiring Diagrams, Electrical Wiring)
Sensors Controls:
Yes (Sensors, Oil Sensor, Pressure Sensor, Oil Pressure Sensor, Oxygen Sensor, Door Jamb Switch)
Lighting:
Yes (Interior Lighting, Lights, HID, Projector, Headlight Replacement, Taillight Replacement, Bulb Replacement, Fogs, Foglight, Foglight Replacement, Third Brake Light, Driving Lights, Fog Lights, Interior Lights, Lighting, Tail Lights, Backup Lights, Turn Signal, Side Markers, Headlight Relay, Starter Relay, Ignition Relay)
Starting Charging:
Yes (Alternator, Alternator Pulley, Starter, Recoil Starter, Starter Replacement, Battery, Battery Replacement)
Body Frame
Exterior Panels:
Yes (Air Deflector, Air Hose, Clutch Hose, Brake Hose, Air Seals, Fan Cover, Filter Cover, Filter Housing, Sleeve, Bumper, Front Bumper, Rear Bumper, Fender, Doors, Emblem, Fuel Cap, Fuel Door, Grilles, Front Grille, Hood, Mud Guards, Mud Flaps, Trim, Trim Replacement, Turn Signal)
Interior Components:
Yes (Dashboard, Dash Replacement, Air Bags, CD Player Replacement, Glovebox, Center Console, Console Replacement, Floor Mat, Cargo Liners, Consoles, Organizers, Leather, Steering Wheel, Shifter, Pedals, Hub Caps, Wheel Cover)
Glass Wipers:
Yes (Glass, Window, Windshield, Wiper Blade, Wiper Motor, Washer Pump)
Procedures Included
Maintenance:
Yes (Oil Change, Transmission Change, Fluid Change, Air Filter Replacement, Fuel Filter Replacement, Brake Change, Tire Rotation)
Repair:
Yes (Complete engine rebuild, transmission overhaul, brake system repair, suspension and steering system service, electrical component replacement, body panel repair and replacement)
Troubleshooting:
Yes (Diagnostic procedures, fault finding, electrical system troubleshooting)
Installation:
Yes (Component installation, accessory fitting guidance implied by factory specifications)
Technical Depth
Depth:
Comprehensive Factory Workshop Manual covering all aspects of repair and maintenance.
Special Procedures:
Yes (Machining, Balancing, Torque Specs, Torque Values, Alignment)
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Keyword Searchable
Zoom Functionality:
Yes (Zoom In/Out)
Printability:
Yes (Printable)
Print Quality
Quality:
Factory Quality
Binding Type
Binding:
N/A (PDF Download)
Paper Type
Paper:
N/A (PDF Download)
⚙️ Engine Specifications
Primary Engine
Configuration:
Liquid-cooled, DOHC, 5-valve, Four-stroke Single
Displacement:
449cc
Bore X Stroke:
95.0 mm x 63.1 mm
Compression Ratio:
11.2:1 (typical, may vary slightly by year)
Performance
Horsepower Est:
Approx. 40-45 HP (stock, may vary)
Torque Est:
Approx. 30-33 lb-ft (stock, may vary)
Fuel System
Carburetor:
Mikuni BSR33/1 (typical, may vary by year)
Fuel Type:
Unleaded gasoline, 87-91 octane recommended
Lubrication
Oil Capacity:
Approx. 1.90 L (with filter change)
Oil Type:
Yamalube 4 (or equivalent) SAE 10W-30 API SG or higher
Cooling System
Type:
Forced liquid cooling
🔧 Transmission
Standard
Type:
5-speed constant mesh with reverse
Features
Clutch Type:
Wet multi-plate
📐 Dimensions
Exterior
Length:
Approx. 1,845 mm (72.6 in)
Width:
Approx. 1,240 mm (48.8 in)
Height:
Approx. 1,055 mm (41.5 in)
Weights
Dry Weight:
Approx. 179 kg (395 lbs)
Fuel Capacity:
Approx. 10 L (2.6 gal)
🛡️ Safety Features
Ratings
Crash Test Data:
N/A (ATV, not subject to standard automotive crash testing)
Active Features
Braking System:
Hydraulic disc brakes front and rear.
Passive Features
Hand Guards:
Integrated hand guards for rider protection.
💡 Technology Features
Infotainment
Features:
Basic instrumentation (speedometer, odometer, engine hour meter, neutral indicator). No advanced infotainment systems.
Driver Assistance
Features:
No electronic driver assistance features. Focus is on raw performance.
Connectivity
Features:
No Bluetooth or Wi-Fi connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 10 hours of operation or monthly, whichever comes first (refer to manual for exact specifications).
Air Filter Cleaning:
Recommended every 5 hours of operation or after dusty rides.
Spark Plug Replacement:
Refer to manual for mileage/hour-based recommendations.
Fluid Specifications
Coolant Type:
Yamaha Silicone Coolant (or equivalent) pre-mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Carburetor Tuning:
Carburetor jetting and adjustment can be critical for optimal performance, especially at different altitudes or with aftermarket modifications. Manual covers precise tuning procedures.
Camchain Tensioner:
Some models may experience wear on the cam chain tensioner; manual provides inspection and replacement guidelines.
Valve Adjustment:
Regular valve lash adjustments are crucial for engine longevity and performance. Manual details the precise procedure and specifications.
📚 Vehicle History
Brand Heritage
Yamaha Legacy:
Yamaha has a long and successful history in motorsports, particularly with performance motorcycles and ATVs.
Model Evolution
Yfz450 Intro:
The YFZ450 was introduced in 2004 as Yamaha's flagship sport ATV, featuring a lightweight aluminum frame and a powerful 450cc engine derived from their motocross bikes.
Year Updates:
Minor revisions and updates occurred throughout the 2003-2009 model years, primarily in suspension tuning, graphics, and some internal engine components. The manual covers these specific factory variations.
Production
Manufacturing Location:
Primarily manufactured in Japan, with some components sourced globally.
🏆 Awards & Recognition
Recognitions
Motorsports Success:
The YFZ450 platform has a strong record of success in professional ATV racing and championships.
Ratings
Consumer Reviews:
Consistently rated highly by enthusiasts for its power, handling, and racing pedigree.
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