Yamaha YFZ450S (designated as 5TG1) is powered by 439cc 4 stroke DOHC liquid cooled engine teamed with a 5 speed manual transmission, wet multiple disc clutch type.
This manual is an all in one manual, covers service /repair manual and electric wiring diagram useful for those who own Yamaha YZF-450S and want to repair/ service the ATV theirself.
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 ]
