2004 YAMAHA YZ450F engine

SPEC
2 - 1
GENERAL SPECIFICATIONS
EC200000
SPECIFICATIONS
EC211000
GENERAL SPECIFICATIONS
Model name: YZ450FS (USA)
YZ450F (EUROPE)
YZ450F(S) (CDN, AUS, NZ, ZA)
Model code number: 5XD1 (USA)
5XD2 (EUROPE)
5XD4 (CDN, AUS, NZ, ZA)
Dimensions:
Overall length 2,171 mm (85.5 in)
Overall width 827 mm (32.6 in)
Overall height 1,303 mm (51.3 in)
Seat height 995 mm (39.2 in)
Wheelbase 1,485 mm (58.5 in)
Minimum ground clearance 371 mm (14.6 in)
Dry weight:
Without oil and fuel 100.0 kg (220 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 449 cm
3 (15.8 Imp oz, 15.2 US oz)
Bore × stroke 95.0 × 63.4 mm (3.74 × 2.50 in)
Compression ratio 12.5 : 1
Starting system Kick starter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For USA and CDN)
At 5 ˚C (40 ˚F) or higher Å
Yamalube 4 (20W-40) or SAE 20W-40 type SG
motor oil (Non-Friction modified)
At 15 ˚C (60 ˚F) or lower ı
Yamalube 4 (10W-30) or SAE 10W-30 type SG
motor oil (Non-Friction modified) and/or
Yamalube 4-R (15W-50) (Non-Friction modi-
fied)
(Except for USA and CDN)
API “SG” or higher grade
-20
-4-10
140
3010
5020
6830
8640 50
104
122°CTemp.
°F
10W-30
10W-40
20W-40
20W-50
15W-40

SPEC
2 - 2
GENERAL SPECIFICATIONS
Oil capacity:
Engine oil
Periodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt)
With oil filter replacement 1.1 L (0.97 Imp qt, 1.16 US qt)
Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes): 1.2 L (1.06 Imp qt, 1.27 US qt)
Air filter: Wet type element
Fuel:
Type Premium unleaded gasoline only with a research
octane number of 95 or higher. (Except for ZA)
Premium gasoline (For ZA)
Tank capacity 7.0 L (1.54 Imp gal, 1.85 US gal)
Carburetor:
Type FCR MX39
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type: Wet, multiple-disc
Transmission: USA, CDN, ZA,
AUS, NZEUROPE
Primary reduction system Gear←
Primary reduction ratio 62/22 (2.818)←
Secondary reduction system Chain drive←
Secondary reduction ratio 48/14 (3.429) 47/14 (3.357)
Transmission type Constant mesh,
4-speed←
Operation Left foot operation←
Gear ratio: 1st 27/14 (1.929)←
2nd 25/16 (1.563)←
3rd 23/18 (1.278)←
4th 21/20 (1.050)←
Chassis:
Frame type Semi double cradle
Caster angle 27.2˚
Trail 118 mm (4.65 in)
Tire:
Type With tube
Size (front) 80/100-21 51M (For USA, CDN, ZA, AUS, NZ
and F)
80/100-21 51R (For EUROPE except F)
Size (rear) 110/90-19 62M (For USA, CDN, ZA, AUS, NZ
and F)
110/90-19 NHS (For EUROPE except F)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm
2, 15 psi)
2

SPEC
2 - 4
MAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.05 mm
(0.002 in)
Cylinder:
Bore size 95.00 ~ 95.01 mm
(3.7402 ~ 3.7406 in)----
Out of round limit ---- 0.05 mm
(0.002 in)
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000 ~ 22.021 mm
(0.8661 ~ 0.8670 in)----
Camshaft journal diameter 21.967 ~ 21.980 mm
(0.8648 ~ 0.8654 in)----
Shaft-to-cap clearance 0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)0.08 mm
(0.003 in)
Cam dimensions
Intake“A”31.200 ~ 31.300 mm
(1.2283 ~ 1.2323 in)31.100 mm
(1.2244 in)
“B”22.550 ~ 22.650 mm
(0.8878 ~ 0.8917 in)22.450 mm
(0.8839 in)
Exhaust“A”30.950 ~ 31.050 mm
(1.2185 ~ 1.2224 in)30.850 mm
(1.2146 in)
“B”22.494 ~ 22.594 mm
(0.8856 ~ 0.8895 in)22.394 mm
(0.8817 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
A
B

SPEC
2 - 8
MAINTENANCE SPECIFICATIONS
Clutch:
Friction plate thickness 2.92 ~ 3.08 mm
(0.115 ~ 0.121 in)2.8 mm
(0.110 in)
Quantity 9 ----
Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ----
Quantity 8 ----
Warp limit ---- 0.1 mm
(0.004 in)
Clutch spring free length 50 mm (1.97 in) 49 mm
(1.93 in)
Quantity 6 ----
Clutch housing thrust clearance 0.10 ~ 0.35 mm
(0.0039 ~ 0.0138 in)----
Clutch housing radial clearance 0.010 ~ 0.044 mm
(0.0004 ~ 0.0017 in)----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm
(0.002 in)
Kick starter:
Type Ratchet type ----
Carburetor:
USAEUROPE, CDN,
ZA, AUS, NZ
I. D. mark 5TA1 00 5XD2 10 ----
Main jet (M.J) #165 #172 ----
Main air jet (M.A.J)ø2.0←----
Jet needle - clip position (J.N) NCVQ-4 OBEMR-3 ----
Cutaway (C.A) 1.5←----
Pilot jet (P.J) #42 #45 ----
Pilot air jet (P.A.J) #100←----
Pilot outlet (P.O)ø0.9←----
Pilot screw (example) (P.S) 2←----
Bypass (B.P)ø1.0←----
Valve seat size (V.S)ø3.8←----
Starter jet (G.S) #72←----
Float height (F.H) 8 mm (0.31 in)←----
Engine idle speed 1,900 ~
2,100 r/min←----
Intake vacuum 28.0 ~ 33.3 kPa
(210 ~ 250 mmHg,
8.27 ~ 9.84 inHg)
←----
Hot starter lever free play 3 ~ 6 mm
(0.12 ~ 0.24 in)←---- Item Standard Limit

SPEC
2 - 11
MAINTENANCE SPECIFICATIONS
Part to be tightened Thread size Q’tyTightening torque
Nm m·kg ft·lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1
M8 × 1.25 1 15 1.5 11
(bolt) M10 × 1.25 4 Refer to NOTE.*
1
(nut) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Timing chain guide (rear) M6 × 1.0 2 10 1.0 7.2
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4
(bolt) M8 × 1.25 1 24 2.4 17
Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 16 1.6 11
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
Clamp (cylinder head side) M5 × 0.8 1 3 0.3 2.2
Clamp (carburetor side) M4 × 0.7 1 3 0.3 2.2
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Air filter element M6 × 1.0 1 2 0.2 1.4
Radiator panel (upper) M6 × 1.0 2 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Radiator pipe 1, 2 M10 × 1.0 2 10 1.0 7.2
Impeller M8 × 1.25 1 14 1.4 10
Water pump housing cover M6 × 1.0 3 10 1.0 7.2
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 10 1.0 7.2
Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2
Oil filter cover M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 M10 × 1.25 1 20 2.0 14
M8 × 1.25 2 18 1.8 13
Oil delivery pipe 2 M6 × 1.0 1 10 1.0 7.2
Oil hose M6 × 1.0 2 8 0.8 5.8
Oil check bolt M6 × 1.0 1 10 1.0 7.2

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 - 18
SPEC
GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS
EC220001
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are included in the applicable sec-
tions of this book. To avoid warpage, tighten
multi-fastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter
EC230000
DEFINITION OF UNITS
A
(Nut)B
(Bolt)TORQUE
SPECIFICATION
Nm m•kg ft•lb
10 mm
12 mm
14 mm
17 mm
19 mm
22 mm6 mm
8 mm
10 mm
12 mm
14 mm
16 mm6
15
30
55
85
1300.6
1.5
3.0
5.5
8.5
134.3
11
22
40
61
94
Unit Read Definition Measure
mm
cmmillimeter
centimeter10
-3 meter
10-2 meterLength
Length
kg kilogram 10
3 gram Weight
N Newton 1 kg × m/sec
2 Force
Nm
m • kgNewton meter
Meter kilogramN × m
m × kgTorque
Torque
Pa Pascal N/m
2Pressure
N/mm Newton per millimeter N/mm Spring rate
L
cm
3 Liter
Cubic centimeter—
—Volume or capacity
Volume or capacity
r/min Revolution per minute—Engine speed

2 - 21
SPECCABLE ROUTING DIAGRAM
EC240000
CABLE ROUTING DIAGRAM
1Fuel tank breather hose
2Oil tank breather hose
3Hot starter cable
4Radiator hose 4
5Clutch cable
6Cylinder head breather hose
7Radiator hose 1
8Hose guide
9Brake hose
0“ENGINE STOP” button lead
AClamp
BSub wire harness
CTPS (throttle position sen-
sor) lead
DNeutral switch lead
EOil hoseFRadiator breather hose
GCDI magneto lead
HCarburetor breather hose
IOverflow hose
ÅInsert the end of the fuel tank
breather hose into the hole in
the steering shaft cap.
ıPass the hot starter cable
between the cylinder head
breather hose, oil tank breather
hose and ignition coil, then on
the outside of the left engine
bracket.
ÇPass the clutch cable through the
cable guide.ÎPass the cylinder head breather
hose on the outside of the radia-
tor hose 1 and on the inside of the
radiator pipe (radiator hose 4).
‰Pass the clutch cable through the
cable guides.
ÏPass the clutch cable in front of
the lower radiator mounting boss.
ÌFit the brake hose into the
guides on the protector.
ÓFasten the “ENGINE STOP”
button lead and sub wire har-
ness to the frame at the protect-
ing tube of the sub wire harness
with a plastic locking tie and cut
off the tie end.
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