Yamaha YFZ450S YFZ 450 2005 QUAD ATV Workshop Service Repair Manual

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Type: Atv

Vendor:

Sku: 88159

Tags: 2005 ATV Powersports Yamaha YFZ 450 YFZ Models YFZ450S

Product variants

Description

The YFZ450S, a high-performance All-Terrain Vehicle (ATV) or Quad Bike, was produced in 2005. This model is renowned for its aggressive sport ATV design, engineered for motocross and desert racing. Key features include its powerful 449 cc liquid-cooled, single-cylinder engine, a lightweight aluminum frame, and independent double wishbone front suspension, all contributing to its exceptional handling and performance capabilities. The YFZ450S represents a commitment to delivering top-tier off-road riding experiences. This comprehensive workshop service repair manual provides extensive guidance for the YFZ450S (chassis code 3GD). Covering a wide array of systems, including the engine, fuel injection, electrical, cooling, and chassis components, this English-language manual offers detailed maintenance procedures, troubleshooting steps, repair instructions, and technical specifications. With clear, step-by-step instructions and detailed diagrams, it is an invaluable resource for professional technicians, ATV enthusiasts, and DIY mechanics aiming to maintain, repair, or restore their vehicle to optimal condition.

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

YFZ450S

Model Variant:

YFZ 450 QUAD ATV

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Target Audience:

Professional technicians, ATV enthusiasts, DIY mechanics, and restoration specialists.

Key Features

Illustration Quality:

Illustrated with clear, step-by-step instructions and detailed diagrams.

Usability:

Designed for immediate problem-solving and comprehensive repair guidance.

Value Proposition

Cost Saving:

Enables owners to perform their own repairs and maintenance, saving on professional labor costs.

📋 Manual Details

Coverage Areas

Vehicle Type:

All-Terrain Vehicle (ATV) / Quad Bike

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine service, overhaul, troubleshooting, including carburetor/fuel injection, ignition, lubrication, and cooling.

Chassis:

Frame, suspension (front and rear), steering, swingarm, and wheel bearings.

Cooling System:

Radiator, coolant, water pump, hoses, and fan operation.

Fuel Injection System:

Throttle body, injectors, fuel pump, sensors (TPS, MAP, IAT), ECM troubleshooting.

Electrical System:

Wiring diagrams, battery, charging system (stator, rectifier/regulator), lighting, starter motor, ignition system components.

General Information:

Includes vehicle identification, safety precautions, general specifications, and break-in procedures.

Specifications:

Comprehensive list of all technical specifications, torque values, tolerances, and electrical data.

Procedures Included

Maintenance:

Periodic checks, adjustments, lubrication, filter changes, fluid checks and replacements.

Troubleshooting:

Comprehensive diagnostic procedures for common and uncommon issues across all systems.

Repair:

Step-by-step instructions for disassembly, repair, and reassembly of all major components and sub-assemblies.

Restoration:

Guidance for restoring the vehicle to original specifications, including detailed component information.

Diagnosis:

Detailed methods for diagnosing faults using specifications, test procedures, and visual inspection.

Troubleshooting Sections:

Specific sections dedicated to diagnosing issues with starting, engine performance, electrical faults, and chassis components.

Technical Depth

Depth:

Expert level, covering everything from basic maintenance to complete engine rebuilds and advanced electrical diagnostics, suitable for professional technicians and experienced DIYers.

Wiring Diagrams:

Detailed and accurate electrical wiring diagrams are provided for complete system understanding and troubleshooting.

Exploded Views:

Includes exploded views of all major components, aiding in disassembly, assembly, and part identification.

📊 Manual Specifications

File Format

Digital Delivery:

Print Quality

Printable:

Yes, full print capability

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

File Size

Max File Size:

Up to 5 GB (Note: Actual size may vary)

Compatibility

Operating Systems:

Windows, Linux, Mac OS

Software Requirements

PDF Reader:

Any standard PDF reader (e.g., Adobe Acrobat Reader)

Unzipping Software:

WinZip or WinRAR recommended for zipped files

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, 4-valve, Liquid-cooled, Single-cylinder

Displacement:

449 cc

Bore X Stroke:

95 mm x 63.4 mm

Compression Ratio:

11.2:1

Performance

Horsepower Estimate:

Approximately 50-55 HP (subject to specific tuning and exhaust)

Torque Estimate:

Approximately 45-48 Nm (subject to specific tuning and exhaust)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with 42mm throttle body

Fuel Type:

Unleaded gasoline, minimum 91 octane

Ignition

Ignition System:

TCI (Transistor Controlled Ignition) with digital advance

Lubrication

Lubrication System:

Wet sump with dual oil pumps

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh manual with reverse

Features

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain, 520 pitch

📐 Dimensions

Weights

Dry Weight:

Approximately 177 kg (390 lbs)

Wet Weight:

Approximately 182 kg (401 lbs) with all fluids

Exterior

Length:

1,790 mm (70.5 in)

Width:

1,220 mm (48.0 in)

Height:

1,045 mm (41.1 in)

Wheelbase:

1,270 mm (50.0 in)

Ground Clearance:

250 mm (9.8 in)

Seat Height:

810 mm (31.9 in)

Tires

Front Tire Size:

AT21x7-10

Rear Tire Size:

AT20x10-9

Suspension

Front Suspension Type:

Independent double wishbone with adjustable shocks

Rear Suspension Type:

Swingarm with adjustable shock

Brakes

Front Brake Type:

Dual hydraulic disc

Rear Brake Type:

Single hydraulic disc

💡 Technology Features

Infotainment

Features:

N/A (Sport ATV, focus is on performance and handling; typically lacks advanced electronics like infotainment systems).

Driver Assistance

Features:

N/A (Sport ATV, no electronic driver aids like traction control or ABS are standard).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 20 hours or annually, whichever comes first (refer to manual for specific details).

Air Filter Cleaning:

Every 10 hours or as needed in dusty conditions.

Spark Plug Replacement:

Check every 20 hours, replace as needed.

Fluid Specifications

Engine Oil Type:

Yamalube 4 (or equivalent) 10W-40 API SG or higher

Engine Oil Capacity:

1.90 L (2.01 US qt) for oil change, 2.10 L (2.22 US qt) for complete disassembly.

Coolant Type:

High-quality ethylene glycol-based antifreeze, 50% mixture with distilled water.

Brake Fluid Type:

DOT 4

Known Issues

Common Problems:

Potential issues include starter clutch wear, valve guide wear, and occasional electrical component failures, especially with modifications. Overheating can occur if the cooling system is not maintained.

Typical Repairs:

Regular maintenance, proper jetting/EFI tuning, and addressing vibration concerns can mitigate many common issues.

📚 Vehicle History

Brand Heritage

Manufacturer:

Yamaha Motor Company, Ltd.

Origin:

Japan

Model Evolution

Introduction Year:

Key Development:

The YFZ450 was developed as a high-performance sport ATV, aiming to dominate motocross and desert racing. It featured a revolutionary aluminum frame and a powerful 5-valve engine derived from Yamaha's motocross bikes.

Production

Manufacturing Location:

Japan