Yamaha 2003 YFZ450S Manuals

Manuals and User Guides for Yamaha 2003 YFZ450S. We have 1 Yamaha 2003 YFZ450S manual available for free PDF download: Service Manual

Yamaha 2003 YFZ450S Service Manual

Yamaha 2003 YFZ450S Service Manual (355 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 15.28 MB
Table of contents
Specifications5................................................................................................................................................................
Engine7................................................................................................................................................................
Table Of Contents9................................................................................................................................................................
Machine Identification19................................................................................................................................................................
Important Information20................................................................................................................................................................
Lock Washers/plates And Cotter Pins21................................................................................................................................................................
Checking The Connections22................................................................................................................................................................
Special Tools23................................................................................................................................................................
General Specifications27................................................................................................................................................................
Engine Specifications30................................................................................................................................................................
Cooling System35................................................................................................................................................................
Chassis Specifications38................................................................................................................................................................
Electrical Specifications40................................................................................................................................................................
Tightening Torques42................................................................................................................................................................
Carburetor43................................................................................................................................................................
Chassis Tightening Torques45................................................................................................................................................................
How To Use The Conversion Table47................................................................................................................................................................
Lubrication Points And Lubricant Types48................................................................................................................................................................
Coolant Flow Diagrams50................................................................................................................................................................
Oil Flow Diagrams52................................................................................................................................................................
Cable Routing54................................................................................................................................................................
Introduction72................................................................................................................................................................
Seat, Fenders And Fuel Tank74................................................................................................................................................................
Foot Protectors And Engine Skid Plate75................................................................................................................................................................
Headlights And Front Fender76................................................................................................................................................................
Rear Fender77................................................................................................................................................................
Fuel Tank78................................................................................................................................................................
Adjusting The Engine Idling Speed84................................................................................................................................................................
Adjusting The Throttle Lever Free Play85................................................................................................................................................................
Adjusting The Speed Limiter87................................................................................................................................................................
Checking The Spark Plug88................................................................................................................................................................
Checking The Ignition Timing89................................................................................................................................................................
Checking The Engine Oil Level90................................................................................................................................................................
Changing The Engine Oil92................................................................................................................................................................
Adjusting The Clutch Cable95................................................................................................................................................................
Cleaning The Air Filter Element97................................................................................................................................................................
Checking The Coolant Level99................................................................................................................................................................
Checking The Coolant Temperature Warning Light103................................................................................................................................................................
Cleaning The Spark Arrester104................................................................................................................................................................
Chassis105................................................................................................................................................................
Adjusting The Parking Brake106................................................................................................................................................................
Checking The Brake Fluid Level107................................................................................................................................................................
Checking The Front Brake Pads108................................................................................................................................................................
Checking The Rear Brake Pads109................................................................................................................................................................
Adjusting The Rear Brake Light Switch110................................................................................................................................................................
Bleeding The Hydraulic Brake System111................................................................................................................................................................
Adjusting The Shift Pedal113................................................................................................................................................................
Adjusting The Drive Chain Slack114................................................................................................................................................................
Checking The Steering System115................................................................................................................................................................
Adjusting The Toe-in116................................................................................................................................................................
Checking The Front And Rear Shock Absorbers117................................................................................................................................................................
Adjusting The Front Shock Absorbers118................................................................................................................................................................
Adjusting The Rear Shock Absorber120................................................................................................................................................................
Checking The Tires124................................................................................................................................................................
Checking The Wheels126................................................................................................................................................................
Lubricating The Levers And Pedals127................................................................................................................................................................
Electrical System128................................................................................................................................................................
Checking The Fuses135................................................................................................................................................................
Adjusting The Headlight Beam136................................................................................................................................................................
Replacing A Headlight Bulb137................................................................................................................................................................
Engine Removal139................................................................................................................................................................
Installing The Exhaust Pipe And Muffler140................................................................................................................................................................
Leads, Cables And Hoses142................................................................................................................................................................
Engine Mounting Bolts144................................................................................................................................................................
Installing The Engine146................................................................................................................................................................
Camshafts147................................................................................................................................................................
Removing The Camshafts149................................................................................................................................................................
Checking The Camshafts150................................................................................................................................................................
Checking The Camshaft Sprockets152................................................................................................................................................................
Checking The Timing Chain Tensioner153................................................................................................................................................................
Cylinder Head156................................................................................................................................................................
Removing The Cylinder Head158................................................................................................................................................................
Checking The Oil Delivery Pipe159................................................................................................................................................................
Valves And Valve Springs162................................................................................................................................................................
Removing The Valves And Valve Springs164................................................................................................................................................................
Checking The Valves And Valve Springs165................................................................................................................................................................
Checking The Valve Lifters170................................................................................................................................................................
Cylinder And Piston172................................................................................................................................................................
Removing The Piston173................................................................................................................................................................
Checking The Piston Rings175................................................................................................................................................................
Checking The Piston Pin176................................................................................................................................................................
Installing The Piston178................................................................................................................................................................
Installing The Cylinder179................................................................................................................................................................
A.c. Magneto180................................................................................................................................................................
Removing The A.c. Magneto Rotor182................................................................................................................................................................
Checking The Starter Clutch183................................................................................................................................................................
Checking The Torque Limiter184................................................................................................................................................................
Clutch186................................................................................................................................................................
Removing The Clutch188................................................................................................................................................................
Checking The Clutch Plates189................................................................................................................................................................
Checking The Clutch Boss190................................................................................................................................................................
Installing The Clutch191................................................................................................................................................................
Balancer193................................................................................................................................................................
Removing The Balancer Drive Gear And Balancer Driven Gear194................................................................................................................................................................
Installing The Balancer Drive Gear And Balancer Driven Gear195................................................................................................................................................................
Oil Pump196................................................................................................................................................................
Checking The Oil Pump198................................................................................................................................................................
Shift Shaft199................................................................................................................................................................
Checking The Shift Shaft201................................................................................................................................................................
Installing The Shift Shaft202................................................................................................................................................................
Crankcase203................................................................................................................................................................
Oil Seal And Bearing205................................................................................................................................................................
Separating The Crankcase206................................................................................................................................................................
Checking The Timing Chain And Guide207................................................................................................................................................................
Assembling The Crankcase208................................................................................................................................................................
Crankshaft210................................................................................................................................................................
Removing The Crankshaft211................................................................................................................................................................
Installing The Crankshaft212................................................................................................................................................................
Transmission213................................................................................................................................................................
Main Axle214................................................................................................................................................................
Drive Axle215................................................................................................................................................................
Checking The Shift Forks216................................................................................................................................................................
Assembling The Main Axle And Drive Axle217................................................................................................................................................................
Installing The Transmission218................................................................................................................................................................
Radiator219................................................................................................................................................................
Checking The Radiator221................................................................................................................................................................
Installing The Radiator222................................................................................................................................................................
Water Pump223................................................................................................................................................................
Checking The Water Pump225................................................................................................................................................................
Disassembling The Carburetor230................................................................................................................................................................
Assembling The Carburetor232................................................................................................................................................................
Adjusting The Accelerator Pump Timing233................................................................................................................................................................
Installing The Carburetor234................................................................................................................................................................
Front And Rear Wheels236................................................................................................................................................................
Rear Wheels238................................................................................................................................................................
Checking The Brake Discs240................................................................................................................................................................
Installing The Front Wheel Hub Bearings241................................................................................................................................................................
Installing The Wheel Hubs242................................................................................................................................................................
Rear Axle And Rear Axle Hub243................................................................................................................................................................
Removing The Rear Axle245................................................................................................................................................................
Checking The Rear Axle246................................................................................................................................................................
Installing The Driven Sprocket247................................................................................................................................................................
Front And Rear Brakes248................................................................................................................................................................
Rear Brake Pads249................................................................................................................................................................
Replacing The Front Brake Pads250................................................................................................................................................................
Replacing The Rear Brake Pads252................................................................................................................................................................
Front Brake Master Cylinder254................................................................................................................................................................
Rear Brake Master Cylinder256................................................................................................................................................................
Checking The Master Cylinders259................................................................................................................................................................
Assembling The Front Brake Master Cylinder260................................................................................................................................................................
Installing The Front Brake Master Cylinder261................................................................................................................................................................
Installing The Rear Brake Master Cylinder262................................................................................................................................................................
Front Brake Calipers264................................................................................................................................................................
Rear Brake Caliper266................................................................................................................................................................
Removing The Parking Brake Cable269................................................................................................................................................................
Checking The Front And Rear Brake Calipers270................................................................................................................................................................
Assembling The Front Brake Calipers271................................................................................................................................................................
Installing The Front Brake Calipers273................................................................................................................................................................
Installing The Rear Brake Caliper274................................................................................................................................................................
Steering System276................................................................................................................................................................
Removing The Front Brake Light Switch And Clutch Switch278................................................................................................................................................................
Installing The Handlebar279................................................................................................................................................................
Installing The Clutch Lever280................................................................................................................................................................
Steering Stem281................................................................................................................................................................
Removing The Bearing Retainer283................................................................................................................................................................
Installing The Lock Washer284................................................................................................................................................................
Tie-rods And Steering Knuckles285................................................................................................................................................................
Removing The Steering Knuckles286................................................................................................................................................................
Front Arms And Front Shock Absorber Assemblies287................................................................................................................................................................
Removing The Front Arms289................................................................................................................................................................
Disposing Of A Front Shock Absorber And Gas Cylinder290................................................................................................................................................................
Checking The Ball Joints291................................................................................................................................................................
Installing The Front Arms292................................................................................................................................................................
Rear Shock Absorber And Relay Arm293................................................................................................................................................................
Handling The Rear Shock Absorber And Gas Cylinder295................................................................................................................................................................
Removing The Rear Shock Absorber296................................................................................................................................................................
Installing The Rear Shock Absorber297................................................................................................................................................................
Swingarm And Drive Chain298................................................................................................................................................................
Removing The Swingarm300................................................................................................................................................................
Checking The Drive Chain302................................................................................................................................................................
Installing The Swingarm303................................................................................................................................................................
Installing The Drive Sprocket304................................................................................................................................................................
Electrical Components305................................................................................................................................................................
Checking Switch Continuity306................................................................................................................................................................
Checking The Switches308................................................................................................................................................................
Checking The Bulbs And Bulb Sockets310................................................................................................................................................................
Checking The Condition Of The Bulb Sockets312................................................................................................................................................................
Ignition System313................................................................................................................................................................
Throttle Override System (t.o.r.s.) Operation314................................................................................................................................................................
Troubleshooting315................................................................................................................................................................
Checking The Throttle Override System318................................................................................................................................................................
Electric Starting System320................................................................................................................................................................
Starting Circuit Cut-off System Operation321................................................................................................................................................................
Starter Motor326................................................................................................................................................................
Checking The Starter Motor328................................................................................................................................................................
Assembling The Starter Motor329................................................................................................................................................................
Charging System330................................................................................................................................................................
Lighting System333................................................................................................................................................................
Checking The Lighting System335................................................................................................................................................................
Signal System337................................................................................................................................................................
Checking The Signaling System339................................................................................................................................................................
Starting Failure/hard Starting347................................................................................................................................................................
Compression System348................................................................................................................................................................
Faulty Gear Shifting349................................................................................................................................................................
Overheating350................................................................................................................................................................
Unstable Handling351................................................................................................................................................................

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