This manual covers the YFZ450, a high-performance sport ATV produced for the 2012-2013 model years. Renowned for its powerful, liquid-cooled, fuel-injected 449cc engine and lightweight aluminum frame, the YFZ450 offers race-inspired ergonomics and long-travel, fully adjustable suspension. Its robust design and agile handling make it a formidable machine for enthusiasts and racers alike, competing strongly in its segment. The YFZ450 is engineered for exceptional off-road capability, featuring strong hydraulic disc brakes and a 5-speed manual transmission with a wet, multi-plate clutch for precise control. This Factory Service Repair Manual provides comprehensive guidance for the maintenance and repair of your YFZ450. It details essential procedures including engine overhaul, fuel and ignition system servicing, transmission and drivetrain maintenance, suspension and brake system repairs, and electrical system diagnostics. The manual includes troubleshooting guides, technical specifications such as torque values and fluid capacities, and assembly/disassembly instructions with exploded views. This resource is invaluable for owners, mechanics, and technicians seeking to ensure the optimal performance, reliability, and longevity of their YFZ450. 🏷️ Basic Information Identification Make: Yamaha Model: YFZ450 Model Designation: YFZ-450 Product Type: Factory Service Repair Manual Generation Generation Identifier: 2012-2013 Model Years Codes Oem Manual Code Reference: Likely derived from Yamaha's internal service documentation structure, specific code not provided. 👋 Introduction Market Position Category: High-performance sport ATV. Target Audience: Enthusiasts, racers, off-road riders, mechanics. Competitive Analysis Segment: Competed against models like the Honda TRX450R, Suzuki LT-R450, and Kawasaki KFX450R. Key Features Engine: High-revving, liquid-cooled, single-cylinder, fuel-injected engine. Chassis: Lightweight, strong aluminum frame with race-inspired ergonomics. Suspension: Long-travel, fully adjustable suspension for superior off-road capability. Braking: Powerful hydraulic disc brakes front and rear. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Yamaha YFZ450 (2012-2013). Specific Topics: Troubleshooting, maintenance schedules, repair procedures, component identification, wiring diagrams. Page Count Estimated Page Count: Typically 300-600 pages for a comprehensive factory service manual of this nature. Specific count not provided. Manual Type Type: Factory Service Repair Manual (Shop Manual) Language Language: English Format Format: PDF File Format: PDF Software Requirements: Adobe Acrobat Reader, WinZip (or similar decompression utility). Compatibility: Windows and Mac operating systems. Searchability: Likely text-searchable PDF, allowing for quick information retrieval. 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, diagnosis, internal components (pistons, cylinders, valves, camshafts, crankshaft). Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator, fuel tank, fuel lines, fuel filter. Ignition System: Ignition coil, CDI unit, spark plug, wiring, timing. Cooling System: Radiator, cooling fan, coolant pump, hoses, thermostat, coolant specifications. Transmission Drivetrain: Clutch system (operation, adjustment, replacement), transmission disassembly, reassembly, lubrication, chain drive, final drive. Suspension: Front and rear suspension systems, shock absorbers, springs, linkages, adjustment procedures, bearing maintenance. Brakes: Hydraulic brake system, brake calipers, master cylinders, brake lines, brake pads, brake discs, bleeding procedures, fluid specifications. Steering: Handlebar assembly, steering stem, steering bearings, tie rods, steering column. Electrical System: Battery, charging system (stator, rectifier/regulator), starter motor, lighting system, switches, fuses, wiring harness. Frame Chassis: Frame inspection, welds, mounting points, body panels, plastics, seat, fenders. Wheels Tires: Wheel bearing maintenance, tire pressure, rim specifications, lug nut torque. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, fault code interpretation (if applicable), symptom-based troubleshooting. Repair: Detailed step-by-step instructions for component removal, installation, rebuilding, and adjustment for all major systems. Diagnostics: Specific diagnostic tests for electrical components, fuel system, ignition system, and mechanical systems. Assembly Disassembly: Exploded views and detailed instructions for complete teardown and reassembly of the ATV. Technical Specifications: Torque values, clearances, fluid capacities, electrical system specifications, performance data. Technical Depth Depth: Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced electrical diagnostics. ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, DOHC, 4-valve, single-cylinder. Displacement: 449cc (approximately). Bore X Stroke: Specifics typically found in the manual, e.g., 95.0 mm x 63.1 mm. Compression Ratio: Typically around 11.2:1 to 12.0:1, specific to model variant. Cooling System: Liquid-cooled. Performance Horsepower Peak: Not explicitly stated in product info, but typically in the range of 40-50 HP for this class. Torque Peak: Not explicitly stated in product info, but typically in the range of 30-35 lb-ft. Fuel System Fuel Delivery: Fuel Injection (EFI) with dual injectors (main and sub) in later models. Throttle Body Size: Typically 42mm or 44mm. Recommended Fuel: Unleaded gasoline, minimum octane rating (e.g., 87 AKI/91 RON) will be specified. 🔧 Transmission Standard Type: 5-speed manual transmission with reverse. Features Clutch Type: Wet, multi-plate clutch. Gear Ratios: Specific ratios will be detailed in the manual for each gear. Final Drive: O-ring sealed chain. Fluid Specifications Transmission Oil Type: Yamalube motorcycle gear oil or equivalent SAE 10W-30 or 10W-40 API SG or higher, meeting specific Yamaha standards. 📐 Dimensions...