YAMAHA YZ450F 2004 Manual PDF

GEN
INFONETTOYAGE ET RANGEMENT
REINIGUNG UND STILLEGUNG
8. Lack- und Chromflächen können mit Auto-
wachs poliert werden. Kombinierte Reini-
ger und Polituren sind zu vermeiden, da sie
oft Scheuermittel enthalten, die den Lack
auf Tank und Verkleidungsteilen beschädi-
gen würden.
9. Nach der Wäsche den Motor anlassen
und warmlaufen lassen.
STILLEGUNG
Vor einer mehr als zweimonatigen Stillegung
sollten einige Schutzvorkehrungen getroffen
werden, um Schäden zu verhindern. Das
Fahrzeug zuerst gründlich reinigen und dann
folgendermaßen zur Stillegung vorbereiten:
1. Kraftstofftank, Kraftstoffleitungen und
Vergaser-Schwimmerkammer entleeren.
2. Die Zündkerze herausschrauben, unge-
fähr einen Teelöffel Motoröl in die Ker-
zenbohrung geben und die Zündkerze
wieder hineinschrauben. Bei gedrücktem
Motorstoppschalter den Kickstarter mehr-
mals durchtreten, um das Öl in der Zylin-
derlaufbuchse zu verteilen.
3. Die Antriebskette lösen, gründlich reini-
gen und dann schmieren. Die Kette wie-
der montieren oder in einem am Rahmen
befestigten Plastikbeutel aufbewahren.
4. Alle Seilzüge ölen.
5. Das Fahrzeug ganz aufbocken, um beide
Räder vom Boden abzuheben.
6. Eine Plastiktüte über die Schalldämpfer-
öffnung stülpen, um Eindringen von
Feuchtigkeit zu verhindern.
7. Bei Lagerung in extrem feuchter oder
salzhaltiger Luft auf alle Metalloberflä-
chen einen dünnen Ölfilm auftragen. Je-
doch niemals Gummiteile oder den Sitz-
bankbezug einölen.
HINWEIS:
Anfallende Reparaturen vor der Stillegung
ausführen. 8. Un encaustique pour automobile peut être
appliqué sur toutes les surfaces peintes et
chromées. Eviter les liquides de nettoyage à
encaustique, car ils contiennent de l’abrasif.
9. Les opérations ci-dessus terminées, lancer le
moteur et le laisser tourner pendant quelques
minutes.
RANGEMENT
Si l’on remise la machine pour 60 jours ou plus, il
faut prendre des mesures de conservation pour évi-
ter sa détérioration. Après un nettoyage soigné, pré-
parer la machine de la manière suivante:
1. Vider le réservoir, les conduites d’essence et
la cuve du carburateur.
2. Déposer la bougie, verser une cuillère à soupe
d’huile moteur SAE 10W-30 dans le trou de
bougie, et la remettre en place. Coupe-circuit
à la position arrêt, donner plusieurs coups de
pédale pour enduire le cylindre d’huile.
3. Déposer la chaîne, la nettoyer soigneusement
au dissolvant et lubrifier. Remonter la chaîne
ou la ranger dans un sachet plastique fermé
fixé au cadre.
4. Lubrifier tous les câbles de commande.
5. Mettre le cadre sur plots pour soulever les
roues du sol.
6. Fixer un sachet plastique sur la sortie du pot
d’échappement pour éviter l’introduction
d’humidité.
7. Si la machine est placée dans une atmosphère
humide ou marine, enduire toutes les surfaces
métalliques nues d’une fine couche d’huile.
Ne pas appliquer d’huile sur les parties en
caoutchouc ou sur la selle.
N.B.:
Avant de ranger la machine, effectuer toutes les
réparations en souffrance.
1 - 20

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 - 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 - 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 - 5
MAINTENANCE SPECIFICATIONS
Cam chain:
Cam chain type/No. of links 98XRH2010-118M/118 ----
Cam chain adjustment method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)----
EX 0.20 ~ 0.25 mm
(0.0079 ~ 0.0098 in)----
Valve dimensions:
“A” head diameter IN 26.9 ~ 27.1 mm
(1.0591 ~ 1.0669 in)----
EX 27.9 ~ 28.1 mm
(1.0984 ~ 1.1063 in)----
“B” face width IN 2.26 mm (0.089 in) ----
EX 2.26 mm (0.089 in) ----
“C” seat width IN 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
EX 0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)1.6 mm
(0.0630 in)
“D” margin thickness IN 1 mm (0.0394 in) 0.85 mm
(0.033 in)
EX 1 mm (0.0394 in) 0.85 mm
(0.033 in)
Stem outside diameter IN 4.475 ~ 4.490 mm
(0.1762 ~ 0.1768 in)4.445 mm
(0.1750 in)
EX 4.965 ~ 4.980 mm
(0.1955 ~ 0.1961 in)4.935 mm
(0.1943 in)
Guide inside diameter IN 4.500 ~ 4.512 mm
(0.1772 ~ 0.1776 in)4.550 mm
(0.1791 in)
EX 5.000 ~ 5.012 mm
(0.1969 ~ 0.1973 in)5.050 mm
(0.1988 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)0.08 mm
(0.003 in)
EX 0.020 ~ 0.047 mm
(0.0008 ~ 0.0019 in)0.10 mm
(0.004 in)
Stem runout limit ---- 0.01 mm
(0.0004 in) Item Standard Limit
Head Diameter
B
Face WidthC
Seat Width
D
Margin ThicknessA

SPEC
2 - 6
MAINTENANCE SPECIFICATIONS
Valve spring:
Free length IN 37.03 mm (1.46 in) 36.03 mm
(1.42 in)
EX 37.68 mm (1.48 in) 36.68 mm
(1.44 in)
Set length (valve closed) IN 27.87 mm (1.10 in) ----
EX 27.38 mm (1.08 in) ----
Compressed force
(installed) IN 111.3 ~ 127.9 N at 27.87 mm
(11.3 ~ 13.0 kg at 27.87 mm,
24.91 ~ 28.66 lb at 1.10 in)----
EX 127.4 ~ 146.4 N at 27.38 mm
(13.0 ~ 14.9 kg at 27.38 mm,
28.66 ~ 32.85 lb at 1.08 in)----
Tilt limit IN ---- 2.5˚/ 1.61 mm
(2.5˚/0.063 in)
EX ---- 2.5˚/1.65 mm
(2.5˚/0.065 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)0.1 mm
(0.004 in)
Piston size “D”94.945 ~ 94.960 mm
(3.738 ~ 3.739 in)----
Measuring point “H”8 mm (0.315 in) ----
Piston off-set 1 mm (0.0394 in) ----
Piston pin bore inside diameter 18.004 ~ 18.015 mm
(0.7088 ~ 0.7093 in)18.045 mm
(0.7104 in)
Piston pin outside diameter 17.991 ~ 18.000 mm
(0.7083 ~ 0.7087 in)17.971 mm
(0.7075 in) Item Standard Limit
*
H
D

SPEC
2 - 7
MAINTENANCE SPECIFICATIONS
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ----
End gap (installed) 0.20 ~ 0.30 mm
(0.008 ~ 0.012 in)0.55 mm
(0.022 in)
Side clearance (installed) 0.030 ~ 0.065 mm
(0.0012 ~ 0.0026 in)0.12 mm
(0.005 in)
2nd ring:
Type Taper ----
Dimensions (B × T) 1.00 × 3.35 mm (0.04 × 0.13 in) ----
End gap (installed) 0.35 ~ 0.50 mm
(0.014 ~ 0.020 in)0.85 mm
(0.033 in)
Side clearance 0.020 ~ 0.055 mm
(0.0008 ~ 0.0022 in)0.12 mm
(0.005 in)
Oil ring:
Dimensions (B × T) 2.0 × 2.9 mm (0.08 × 0.11 in) ----
End gap (installed) 0.2 ~ 0.5 mm (0.01 ~ 0.02 in) ----
Crankshaft:
Crank width “A”61.95 ~ 62.00 mm
(2.439 ~ 2.441 in)----
Runout limit “C”0.03 mm (0.0012 in) 0.05 mm
(0.002 in)
Big end side clearance “D”0.15 ~ 0.45 mm
(0.0059 ~ 0.0177 in)0.50 mm
(0.02 in)
Small end free play “F”0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm
(0.08 in)
Balancer:
Balancer drive method Gear ----
Air filter oil grade: Foam-air-filter oil or equivalent
oil ---- Item Standard Limit
T
B
B
T
B
T

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 - 9
MAINTENANCE SPECIFICATIONS
Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance “A”0.12 mm or less
(0.0047 in or less)0.20 mm
(0.008 in)
Tip clearance “B”0.09 ~ 0.17 mm
(0.0035 ~ 0.0067 in)0.24 mm
(0.009 in)
Side clearance 0.03 ~ 0.10 mm
(0.0012 ~ 0.0039 in)0.17 mm
(0.007 in)
Bypass valve setting pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm
2,
5.69 ~ 11.38 psi)----
Cooling:
Radiator core size
Width 117.8 mm (4.6 in) ----
Height 260 mm (10.2 in) ----
Thickness 32 mm (1.26 in) ----
Radiator cap opening pressure 110 kPa (1.1 kg/cm
2, 15.6 psi) ----
Radiator capacity (total) 0.71 L (0.62 Imp qt, 0.75 US qt) ----
Water pump
Type Single-suction centrifugal pump ----Item Standard Limit