Yamaha 2003 YFZ450S Manuals

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 (375 pages)

Brand: Yamaha | Category: Offroad Vehicle | Size: 15.58 MB

Table of Contents

Table of Contents

7
- Carburetor
  6
- Chassis
  6
- Cooling System
  6
- Electrical
  6
- Engine
  6
- Periodic Checks and Adjustments
  6
- Troubleshooting
  6
  - Table of Contents
    7
- Chapter 1 General Information
  12
- Machine Identification
  12
  - Vehicle Identification Number
    12
  - Model Label
    12
- Important Information
  13
  - Preparation for Removal and Disassembly
    13
  - Replacement Parts
    13
  - Gaskets, Oil Seals and O-Rings
    13
  - Lock Washers/Plates and Cotter Pins
    14
  - Bearings and Oil Seals
    14
  - Circlips
    14
  - Checking the Connections
    15
- Special Tools
  16
- Spec
  21
Chapter 2 Specifications

22
- General Specifications
  24
- Engine Specifications
  27
- Chassis Specifications
  35
- Electrical Specifications
  37
- Tightening Torques
  39
  - Engine Tightening Torques
    39
  - Chassis Tightening Torques
    42
- General Tightening Torque Specifications
  44
- How to Use the Conversion Table
  44
- Lubrication Points and Lubricant Types
  45
  - Engine
    45
- Coolant Flow Diagrams
  47
- Oil Flow Diagrams
  49
- Cable Routing
  51
- Chk Adj
  70
Chapter 3 Periodic Checks and Adjustments

71
- Introduction
  73
- Periodic Maintenance/Lubrication
  73
- Seat, Fenders and Fuel Tank
  75
  - Seat, Fuel Tank Cover and Side Covers
    75
  - Foot Protectors and Engine Skid Plate
    76
  - Headlights and Front Fender
    77
  - Rear Fender
    78
  - Fuel Tank
    79
- Engine
  80
- Chassis
  105
  - Adjusting the Front Brake
    105
  - Adjusting the Brake Lever
    105
  - Adjusting the Rear Brake
    106
  - Adjusting the Parking Brake
    106
  - Checking the Brake Fluid Level
    107
  - Checking the Front Brake Pads
    108
  - Checking the Rear Brake Pads
    109
  - Adjusting the Rear Brake Light Switch
    110
  - Checking the Brake Hoses
    110
  - Bleeding the Hydraulic Brake System
    111
  - Adjusting the Shift Pedal
    113
  - Adjusting the Drive Chain Slack
    114
  - Checking the Steering System
    115
  - Adjusting the Toe-In
    116
  - Checking the Front and Rear Shock Absorbers
    117
  - Adjusting the Front Shock Absorbers
    118
  - Adjusting the Rear Shock Absorber
    120
  - Checking the Tires
    124
  - Checking the Wheels
    126
  - Checking and Lubricating the Cables
    126
  - Lubricating the Levers and Pedals
    127
- Electrical System
  128
  - Checking and Charging the Battery
    128
  - Checking the Fuses
    135
  - Adjusting the Headlight Beam
    136
  - Replacing a Headlight Bulb
    137
- Eng
  139
Chapter 4 Engine

140
- Engine Removal
  144
  - Muffler and Exhaust Pipe
    144
  - Installing the Exhaust Pipe and Muffler
    145
  - Leads, Cables and Hoses
    147
  - Engine Mounting Bolts
    149
  - Installing the Engine
    151
- Camshafts
  152
  - Cylinder Head Cover
    152
  - Camshafts
    153
  - Removing the Camshafts
    154
  - Checking the Camshafts
    155
  - Checking the Camshaft Sprockets
    157
  - Checking the Decompression System
    157
  - Checking the Timing Chain Guide
    157
  - Checking the Timing Chain Tensioner
    158
  - Installing the Camshafts
    158
- Cylinder Head
  161
  - Removing the Cylinder Head
    163
  - Checking the Cylinder Head
    163
  - Checking the Oil Delivery Pipe
    164
  - Checking the Timing Chain Guide
    164
  - Installing the Cylinder Head
    164
- Valves and Valve Springs
  167
- Cylinder and Piston
  177
  - Removing the Piston
    178
  - Checking the Cylinder and Piston
    178
  - Checking the Piston Rings
    180
  - Checking the Piston Pin
    181
  - Installing the Piston
    183
  - Installing the Cylinder
    184
- A.C. Magneto
  185
  - Removing the A.C. Magneto Rotor
    187
  - Checking the Stator Coil and Pickup Coil
    187
  - Checking the Starter Clutch
    188
  - Checking the Torque Limiter
    189
  - Installing the A.C. Magneto Rotor
    189
- Clutch
  191
  - Removing the Clutch
    193
  - Checking the Friction Plates
    193
  - Checking the Clutch Plates
    194
  - Checking the Clutch Springs
    194
  - Checking the Clutch Housing
    194
  - Checking the Clutch Boss
    195
  - Checking the Pressure Plate
    195
  - Checking the Push Rods
    195
  - Checking the Push Lever
    195
  - Checking the Primary Driven Gear
    195
  - Installing the Clutch
    196
- Balancer
  198
- Oil Pump
  201
  - Checking the Oil Pump
    203
- Shift Shaft
  204
  - Checking the Shift Shaft
    206
  - Checking the Stopper Lever
    206
  - Checking the Shift Guide and Shift Lever
    206
  - Checking the Shift Drum Segment
    206
  - Installing the Shift Lever
    206
  - Installing the Shift Shaft
    207
- Crankcase
  208
  - Oil Seal and Bearing
    210
  - Separating the Crankcase
    211
  - Checking the Oil Strainer and Oil Delivery Pipe 2
    211
  - Checking the Timing Chain and Guide
    212
  - Checking the Bearings and Oil Seals
    212
  - Checking the Crankcase
    212
  - Assembling the Crankcase
    213
- Crankshaft
  215
  - Removing the Crankshaft
    216
  - Checking the Crankshaft
    216
  - Installing the Crankshaft
    217
- Transmission
  218
  - Main Axle
    219
  - Drive Axle
    220
  - Checking the Shift Forks
    221
  - Checking the Shift Drum
    221
  - Checking the Transmission
    221
  - Assembling the Main Axle and Drive Axle
    222
  - Installing the Transmission
    223
- Cool
  224
Cool

225
- Chapter 5 Cooling System
  227
- Radiator
  227
  - Checking the Radiator
    229
  - Installing the Radiator
    230
- Water Pump
  231
  - Checking the Water Pump
    233
- Carb
  235
- Chas
  248
Chapter 7 Chassis

249
- Front and Rear Wheels
  251
- Front Wheels
  251
- Rear Wheels
  253
- Checking the Wheel Hubs
  254
- Checking the Wheels
  254
- Checking the Brake Discs
  255
- Installing the Front Brake Discs
  256
- Installing the Front Wheel Hub Bearings
  256
- Installing the Front Wheels
  256
- Installing the Wheel Hubs
  257
- Rear Axle and Rear Axle Hub
  258
  - Removing the Rear Axle
    260
  - Checking the Rear Axle
    261
  - Checking the Driven Sprocket
    261
  - Checking the Brake Disc
    261
  - Installing the Driven Sprocket
    262
  - Installing the Rear Axle
    262
- Front and Rear Brakes
  263
  - Front Brake Pads
    263
  - Rear Brake Pads
    264
  - Replacing the Front Brake Pads
    265
  - Replacing the Rear Brake Pads
    267
  - Front Brake Master Cylinder
    269
  - Rear Brake Master Cylinder
    271
  - Checking the Master Cylinders
    274
  - Assembling the Front Brake Master Cylinder
    275
  - Assembling the Rear Brake Master Cylinder
    275
  - Installing the Front Brake Master Cylinder
    276
  - Installing the Rear Brake Master Cylinder
    277
  - Front Brake Calipers
    279
  - Rear Brake Caliper
    281
  - Removing the Parking Brake Cable
    284
  - Disassembling the Front and Rear Brake Calipers
    284
  - Checking the Front and Rear Brake Calipers
    285
  - Assembling the Front Brake Calipers
    286
  - Assembling the Rear Brake Caliper
    286
  - Installing the Front Brake Calipers
    288
  - Installing the Rear Brake Caliper
    289
- Steering System
  291
  - Handlebar
    291
  - Removing the Front Brake Light Switch and Clutch Switch
    293
  - Removing the Handlebar Grips
    293
  - Checking the Handlebar
    293
  - Installing the Handlebar
    294
  - Installing the Handlebar Grips
    294
  - Installing the Clutch Lever
    295
  - Installing the Brake Master Cylinder
    295
  - Steering Stem
    296
  - Removing the Bearing Retainer
    298
  - Checking the Steering Stem
    298
  - Installing the Bearing Retainer
    298
  - Installing the Steering Stem
    298
  - Installing the Lock Washer
    299
  - Installing the Pitman Arm
    299
  - Tie-Rods and Steering Knuckles
    300
  - Removing the Steering Knuckles
    301
  - Checking the Tie-Rods
    301
  - Checking the Steering Knuckles
    301
  - Installing the Tie-Rods
    301
- Front Arms and Front Shock Absorber Assemblies
  302
- Rear Shock Absorber and Relay Arm
  308
- Swingarm and Drive Chain
  313
  - Removing the Swingarm
    315
  - Checking the Swingarm
    315
  - Checking the Drive Chain
    317
  - Installing the Swingarm
    318
  - Installing the Drive Sprocket
    319
- Elec
  321
Chapter 8 Electrical

322
- Electrical Components
  324
- Checking Switch Continuity
  325
- Checking the Switches
  326
- Checking the Bulbs and Bulb Sockets
  328
- Ignition System
  331
  - Circuit Diagram
    331
  - Throttle Override System (T.o.r.s.) Operation
    332
  - Troubleshooting
    333
  - Checking the Throttle Override System
    337
- Electric Starting System
  339
  - Circuit Diagram
    339
  - Starting Circuit Cut-Off System Operation
    340
  - Troubleshooting
    341
- Starter Motor
  345
  - Checking the Starter Motor
    347
  - Assembling the Starter Motor
    348
- Charging System
  349
  - Circuit Diagram
    349
  - Troubleshooting
    350
- Lighting System
  352
  - Circuit Diagram
    352
  - Troubleshooting
    353
  - Checking the Lighting System
    354
- Signal System
  356
  - Circuit Diagram
    356
  - Troubleshooting
    357
  - Checking the Signaling System
    358
- Cooling System
  362
  - Circuit Diagram
    362
- Trbl Shtg
  366
Trbl Shtg

367
- Troubleshooting
  367
- Chapter 9
  369
- Electrical System
  369
- Fuel System
  369
- Starting Failure/Hard Starting
  369
- Compression System
  370
- Poor Idle Speed Performance
  370
- Poor Medium and High-Speed Performance
  370
- Clutch Slipping/Dragging
  371
  - Clutch Slipping
    371
  - Clutch Dragging
    371
- Faulty Gear Shifting
  371
  - Hard Shifting
    371
  - Shift Pedal Does Not Move
    371
  - Jumps out Gear
    371
- Faulty Brake
  372
  - Poor Braking Effect
    372
- Overheating
  372
- Shock Absorber Malfunction
  372
  - Malfunction
    372
- Lighting System
  373
  - Headlight Does Not Come on
    373
  - Tail/Brake Light Does Not Light
    373
  - Bulb Burnt out
    373
  - Tail/Brake Light Bulb Burnt out
    373
- Unstable Handling
  373

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