2004 YAMAHA YZ450F Shock

CHAPTER 4
ENGINE
SEAT, FUEL TANK
AND SIDE COVERS
..................................4-1
EXHAUST PIPE AND SILENCER
.............4-3
RADIATOR
................................................4-5
CARBURETOR
..........................................4-8
CAMSHAFTS
...........................................4-21
CYLINDER HEAD
....................................4-29
VALVES AND VALVE SPRINGS
............4-33
CYLINDER AND PISTON
........................4-42
CLUTCH
...................................................4-48
OIL FILTER, WATER PUMP AND
CRANKCASE COVER (RIGHT)
..............4-55
BALANCER
.............................................4-62
OIL PUMP
................................................4-65
KICK AXLE AND SHIFT SHAFT
.............4-69
CDI MAGNETO
........................................4-76
ENGINE REMOVAL
.................................4-80
CRANKCASE AND CRANKSHAFT
........4-85
TRANSMISSION, SHIFT CAM
AND SHIFT FORK
...................................4-94
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL
.......5-1
FRONT BRAKE AND REAR BRAKE
.....5-10
FRONT FORK
..........................................5-26
HANDLEBAR
...........................................5-39
STEERING
...............................................5-45
SWINGARM
.............................................5-50
REAR SHOCK ABSORBER
....................5-58

GEN
INFO
1 - 18
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
NOTE:
Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.
Frame to rear frame
Fuel tank to frame
Silencer to rear frame
Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering shaft to frame
Steering shaft to handle crown
Handle crown to handlebar
Front fork to handle crown
Front fork to under bracket
Assembly of links
Link to frame
Link to shock absorber
Link to swingarm
Shock absorber to frame
Tightening of pivot shaft
Tightening of front axle
Tightening of axle holder
Tightening of rear axle
Wheel to sprocket
Caliper to front fork
Brake disc to wheel
Tightening of union bolt
Master cylinder to handlebar
Tightening of air bleeder
Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Master cylinder to frame
Tightening of air bleeder
Fuel tank to fuel cock
Tightening of oil hose clamp Frame construction
Combined seat and tank
Exhaust system
Engine mounting
Steering Steering shaft to
handlebar
Suspension Front Steering shaft to front
fork
Rear For link type
Rear Installation of shock
absorber
Rear Installation of swing-
arm
Wheel Installation of wheel Front
Rear
Brake Front
Rear
Fuel system
Lubrication system

SPEC
2 - 3
GENERAL SPECIFICATIONS
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)
Electrical:
Ignition system CDI magneto

SPEC
2 - 13
MAINTENANCE SPECIFICATIONS
EC212201
CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Taper roller bearing ----
Front suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Front fork travel 300 mm (11.8 in)←----
Fork spring free length 479 mm (18.9 in)←474 mm (18.7 in)
Spring rate, STD K = 4.5 N/mm
(0.459 kg/mm,
25.7 lb/in)K = 4.4 N/mm
(0.449 kg/mm,
25.1 lb/in)----
Optional spring/spacer Yes←----
Oil capacity 662 cm
3
(23.3 Imp oz,
22.4 US oz) 668 cm3
(23.5 Imp oz,
22.6 US oz) ----
Oil level 125 mm (4.92 in) 120 mm (4.72 in) ----

(From top of outer tube with inner
tube and damper rod fully com-
pressed without spring.)105 ~ 135 mm
(4.13 ~ 5.31 in)←----
Oil grade Suspension oil
“01”←----
Inner tube outer diameter 48 mm (1.89 in)←----
Front fork top endZero mm (Zero in)←----
Rear suspension: USA, CDN,
AUS, NZ, ZAEUROPE
Shock absorber travel 132 mm
(5.20 in)←----
Spring free length 260 mm
(10.24 in)275 mm
(10.83 in)----
Fitting length 248 mm
(9.76 in)263 mm
(10.35 in)----
240.5 ~ 258.5 mm
(9.47 ~ 10.18 in)255.5 ~ 273.5 mm
(10.06 ~ 10.77 in)----
Spring rate, STD K = 52.0 N/mm
(5.30 kg/mm,
296.8 lb/in)K = Approx.
52.0 N/mm
(5.30 kg/mm,
296.8 lb/in)----
Optional spring Yes←----
Enclosed gas pressure 1,000 kPa
(10 kg/cm
2,
142 psi)←----
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04 in)

SPEC
2 - 16
MAINTENANCE SPECIFICATIONS
NOTE:
- marked portion shall be checked for torque tightening after break-in or before each race.Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Rear wheel axle and nut M20 × 1.5 1 125 12.5 90
Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30
Nipple (spoke)–72 3 0.3 2.2
Disc cover and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11
Engine mounting:
Engine upper bracket and frame M10 × 1.25 2 55 5.5 40
Engine lower bracket and frame M8 × 1.25 4 34 3.4 24
Engine and frame (front) M10 × 1.25 1 69 6.9 50
Engine and frame (upper) M10 × 1.25 1 55 5.5 40
Engine and frame (lower) M10 × 1.25 1 69 6.9 50
Engine guard (lower) M8 × 1.25 1 34 3.4 24
Engine skid plate mounting M6 × 1.0 6 10 1.0 7.2
CDI unit bracket mounting M6 × 1.0 1 10 1.0 7.2
Pivot shaft and nut M16 × 1.5 1 85 8.5 61
Relay arm and swingarm M14 × 1.5 1 80 8.0 58
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame and frame (upper) M8 × 1.25 1 32 3.2 23
Rear frame and frame (lower) M8 × 1.25 2 29 2.9 21
Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Drive chain tensioner mounting (upper) M8 × 1.25 1 19 1.9 13
Drive chain tensioner mounting (lower) M8 × 1.25 1 20 2.0 14
Chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank mounting M6 × 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1
Fuel tank and hooking screw (fitting band) M6 × 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Seat mounting M8 × 1.25 2 23 2.3 17
Side cover mounting M6 × 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 6 0.6 4.3
Air scoop and radiator panel (lower) M6 × 1.0 2 6 0.6 4.3
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting (front) M6 × 1.0 2 7 0.7 5.1
Rear fender mounting (rear) M6 × 1.0 2 12 1.2 8.7
Number plate M6 × 1.0 1 7 0.7 5.1

2 - 22
SPECCABLE ROUTING DIAGRAM
ÈFasten the “ENGINE STOP”
button lead and sub wire har-
ness to the frame at the pro-
tecting tube for the “ENGINE
STOP” button lead with a plas-
tic locking tie and cut off the tie
end.
ÔFasten the sub wire harness
and hot starter cable to the
frame at the white tape for the
sub wire harness with a plastic
locking tie and cut off the tie
end.
Fasten the sub wire harness to
the frame with a plastic locking
tie and cut off the tie end.
ÒPass the sub wire harness
between the engine brackets.˜Make sure that the TPS cou-
pler does not go outside the
chassis.
ˆFasten the TPS lead to the
frame with a plastic band.
ØFasten the neutral switch lead
and oil hose together with a
plastic locking tie and cut off
the tie end.
∏Fasten the neutral switch lead
to the frame with a plastic
band.
ŒFasten the neutral switch lead,
CDI magneto lead and radiator
breather hose to the frame with
a plastic band.ÂFasten the neutral switch lead,
CDI magneto lead and radiator
breather hose to the frame with
a plastic locking tie and cut off
the tie end.
ÍPass the neutral switch lead,
CDI magneto lead and radiator
breather hose between the
radiator and frame.
ÊFasten the neutral switch lead
and CDI magneto lead to the
cable guide at their protecting
tubes with a plastic locking tie
and cut off the tie end.
ËPass the carburetor breather
hoses and overflow hose so
that all there hoses do not con-
tact the rear shock absorber.
B
0
C-C
D-D
B
A
AB
DD
CC
F
D G
F
D
◊
A
G
A
A
F
AE
A
DC A A A A B A 0
1
2
3
4 5 6 7 89
‰
̉
Ï
‰
Î
Çı ÅÊÓ
È
Ô

Ò

A ˜
ˆ
Ø ∏ Œ ÂÍ
Ë HIH
E

2 - 25
SPECCABLE ROUTING DIAGRAM
1Master cylinder
2Brake hose holder
3Brake hoseÅInstall the brake hose so that its
pipe portion directs as shown and
lightly touches the projection on
the caliper.
ıPass the brake hose into the
brake hose holders.
ÇIf the brake hose contacts the
spring (rear shock absorber), cor-
rect its twist.
ÎInstall the brake hose so that its
pipe portion directs as shown and
lightly touches the projection on
the master cylinder.

3 - 3
INSP
ADJ
MAINTENANCE INTERVALS
FRONT FORK OIL SEAL AND DUST
SEAL
Clean and lube
● ● Lithium base grease
REAR SHOCK ABSORBER
Inspect and adjust
Lube
Retighten
●
●
●
●
●
(After
rain ride)
● Molybdenum disulfide
grease
CHAIN GUARD AND ROLLERS
Inspect
● ●
SWINGARM
Inspect, lube and retighten
● ● Molybdenum disulfide
grease
RELAY ARM, CONNECTING ROD
Inspect, lube and retighten
● ● Molybdenum disulfide
grease
STEERING HEAD
Inspect free play and retighten
Clean and lube
Replace bearing
● ●
●
● Lithium base grease
TIRE, WHEELS
Inspect air pressure, wheel run-out,
tire wear and spoke looseness
Retighten sprocket bolt
Inspect bearings
Replace bearings
Lubricate
●
●
●
●
●
●
●
Lithium base grease
THROTTLE, CONTROL CABLE
Check routing and connection
Lubricate
●
●
●
● Yamaha cable lube or
SAE 10W-30 motor oil
HOT STARTER, CLUTCH LEVER
Inspect free play
●
ItemAfter
break-inEvery
race
Every
third
(or
500 km)Every
fifth
(or
1,000 km)As re-
quiredRemarks