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Clymer Yamaha YFZ450 Repair Manual


This digital edition of the Yamaha YFZ450 manual can be accessed anytime online after purchase and provides care free storage and easy searching capabilities.

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Product Code: M287D



Yamaha YFZ450 Manual

This Clymer ATV manual covers the Yamaha YFZ450 for these years: 2004, 2005, 2006, 2007, 2008, 2009

Note: Does not cover the YFZ450R or YFZ450R SE models.

Clymer ATV repair manuals are the best reference book for repair and service information. The service manual is written for the do-it-yourselfer as well as the experienced mechanic, This repair manual is the cheapest way to keep your four wheeler running properly. This service manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the Yamaha YFZ 450. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail, accuracy and clarity to guide the reader through each service, troubleshooting and repair procedure.

The Yamaha YFZ 450 manual includes the following information:

Quick Reference Data

General Information
Manual Organization/Warnings, cautions and notes/Safety/Serial numbers and information labels/Fasteners/Shop supplies/Tools/Measuring tools/Electrical system fundamentals/Service methods/Storage/Specifications

Starting the engine/Engine spark test/Engine performance/Engine noise/Engine leakdown test/Clutch/External shift mechanism and transmission/Electrical testing/Engine starting system/Brakes/Steering and handling

Lubrication and Maintenance
Pre-ride inspection/Engine oil/Air filter/Control cable inspection and lubrication/Throttle cable and speed limiter adjustment/Clutch lever/Brakes/Drive chain/Tires and wheels/Front wheel bearing inspection/Steering system/Front suspension/Rear suspension/Battery/Cooling system/Carburetor/Crankcase breather hoses/Spark plug/Ignition timing inspection/Compression test/Valve clearance adjustment/Exhaust system/Fastener inspection/Specification

Engine Top End
Exhaust system/Cylinder head cover/Camshafts/Camshaft bearing clearance measurement/Cam chain tensioner/Cam chain and guide/Cylinder head/Valves/Cylinder/Piston and piston rings/Specifications

Engine Lower End
Engine/Torque limiter/Left crankcase cover/Starter idler gear/Flywheel (alternator rotor) and starter clutch/Camshaft chain and guides/Right crankcase cover/Balancer and primary drive gears/Oil pump/Crankcase/Crankcase seal and bearing replacement/Crankshaft/Engine break-in/Specifications

Clutch and External Shift Mechanism
Clutch cover/Clutch/Clutch release lever assembly/External shift mechanism/Clutch cable/Specifications

Transmission and Internal Gearshift Mechanism
Transmission service notes/Mainshaft/Countershaft/Transmission inspection/Shift drum and forks/Specifications

Fuel System and Emission Control
Carburetor/Float adjustment/Carburetor adjustment and rejetting/Air box/Fuel tank/Fuel valve/Throttle cable/Crankcase breather system/Specifications

Electrical System
Electrical component replacement/Continuity testing/Electrical connectors/Negative battery terminal/Battery/Charging system/Alternator/Ignition system/Starter/Starting circuit cutoff system/Starter relay/Lighting system/Cooling system/Throttle position sensor/Switches/Specifications

Cooling System
Cooling system service notes/Pressure test/Hoses and clamps/Radiator/Coolant reservoir/Radiator fan/Water pump housing/Water pump/Specifications

Wheels, Tires and Drive Chain
Wheel/Tires/Sprockets/Drive chain/Specifications

Front Suspension and Steering
Handlebar/Shock absorbers/Front wheel hub/Tie rod/Steering knuckle/Control arms/Steering shaft/Specifications

Rear Axle and Suspension
Wheel hub/Rear axle/Rear axle hub/Shock absorber/Shock linkage/Swing arm/Specifications

Brake fluid selection/Brake service notes/Front brake pads/Front brake caliper/Front master cylinder/Rear brake pads/Rear brake caliper/Rear master cylinder/Rear brake pedal/Brake disc/Front brake hose-tube removal-installation/Rear brake hose removal-installation/Brake system draining/Brake bleeding/Specifications

Seat/Fuel tank cover/Fuel tank shield/Side covers/Front fender/Rear fender/Foot protectors/Footrests/Engine skidplate/Specification


Wiring Diagrams


The Yamaha YFZ450 manual contains the following:

  • Handy thumb-tabs put the chapter you need right at your fingertips.
  • Detailed substeps expand on service procedure information.
  • Notes, cautions and warnings throughout each chapter pinpoint critical information.
  • Numbered instructions guide you through every repair procedure step by step.
  • Bold figure numbers help you quickly match illustrations with instructions.
  • Detailed illustrations, drawings and photos guide you through every service procedure.
  • Exploded views help you identify and examine parts in detail.
  • Numbered table of contents . . . easy to use so that you can find the information you need fast.
  • Clymer repair manuals also make it easy to diagnose and repair electrical system problems on your all terrain vehicle.
  •  Troubleshooting and electrical service procedures are combined with detailed wiring diagrams (color on select titles) for ease of use.

Please note that this digital version is accessed online in zmag format. It remains available to the purchaser indefinitely via the internet but it cannot be printed or downloaded to your computer

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