Yamaha YFZ450S 2004 Service Manual

Yamaha YFZ450S · 2004 · service manual · 355 pages

Yamaha YFZ450S
2004
Service manual
355 pages
ATV

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Spark plug	13 N·m	1.3 kgf·m · 9.4 ft·lb	p. 42
Cylinder head cover Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Camshaft cap Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Cylinder head blind plug screw Screw	37 N·m	3.7 kgf·m · 27 ft·lb	p. 42
Timing chain tensioner Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Timing chain tensioner cap Bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 42
Timing chain guide (intake) Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Cylinder head (exhaust pipe) Stud bolt	15 N·m	1.5 kgf·m · 11 ft·lb	p. 42
Cylinder head (timing chain side) Stud bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 42
Engine oil drain bolt (oil tank) Bolt	19 N·m	1.9 kgf·m · 13 ft·lb	p. 42
Engine oil drain bolt (engine) Bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 42
Oil pump Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Oil pump housing cover Screw	2 N·m	0.2 kgf·m · 1.4 ft·lb	p. 42
Engine oil drain bolt (oil filter) Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Oil delivery pipe 1 Union bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 42
Union bolt	18 N·m	1.8 kgf·m · 13 ft·lb	p. 42
Oil delivery pipe 2 Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Oil gallery bolt Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Exhaust pipe Bolt	24 N·m	2.4 kgf·m · 17 ft·lb	p. 42
Muffler Bolt	34 N·m	3.4 kgf·m · 24 ft·lb	p. 42
Muffler and exhaust pipe Bolt	20 N·m	2 kgf·m · 14 ft·lb	p. 42
Spark arrester Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Silencer cap Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Radiator Bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 42
Radiator fan Bolt	9 N·m	0.9 kgf·m · 6.5 ft·lb	p. 42
Coolant drain bolt Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Water pump inlet pipe Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 42
Cylinder head water jacket Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Water pump housing cover Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Coolant reservoir Bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 43
Clutch cover Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Clutch boss Nut	75 N·m	7.5 kgf·m · 54 ft·lb	p. 43
Push lever shaft plate Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Clutch cable holder Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Crankcase cover Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Parking brake cable holder and Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Left crankcase Bolt	12 N·m	1.2 kgf·m · 8.7 ft·lb	p. 43
Oil strainer Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Crankcase bearing retainer Screw	12 N·m	1.2 kgf·m · 8.7 ft·lb	p. 43
Primary drive gear Nut	75 N·m	7.5 kgf·m · 54 ft·lb	p. 43
Balancer driven gear Nut	50 N·m	5 kgf·m · 36 ft·lb	p. 43
Drive sprocket Nut	75 N·m	7.5 kgf·m · 54 ft·lb	p. 43
Drive axle oil seal retainer Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Limiter cover Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
A.C. magneto cover Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
A.C. magneto rotor Nut	65 N·m	6.5 kgf·m · 47 ft·lb	p. 43
Stator coil Bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 43
A.C. magneto lead holder Bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 43
Pickup coil Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Starter clutch Bolt	16 N·m	1.6 kgf·m · 11 ft·lb	p. 43
Shift drum segment Bolt	30 N·m	3 kgf·m · 22 ft·lb	p. 43
Shift guide Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Stopper lever Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 43
Shift pedal Bolt	12 N·m	1.2 kgf·m · 8.7 ft·lb	p. 43
Throttle cable cover (carburetor) Bolt	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 43
Carburetor joint clamp screw	3 N·m	0.3 kgf·m · 2.2 ft·lb	p. 43
Neutral switch	20 N·m	2 kgf·m · 14 ft·lb	p. 43
Thermo switch 1	28 N·m	2.8 kgf·m · 20 ft·lb	p. 43
Thermo switch 2	28 N·m	2.8 kgf·m · 20 ft·lb	p. 44
Starter motor Bolt	10 N·m	1 kgf·m · 7.2 ft·lb	p. 44
Starter motor lead Nut	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 44
Bush holder assembly and rear Nut	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 44
Bracket nut	30 N·m	3 kgf·m · 22 ft·lb	p. 44
Bracket nut	20 N·m	2 kgf·m · 14 ft·lb	p. 44
Engine stay and frame	33 N·m	3.3 kgf·m · 24 ft·lb	p. 45
Engine stay and engine upper bracket	26 N·m	2.6 kgf·m · 19 ft·lb	p. 45
Engine upper bracket and engine	40 N·m	4 kgf·m · 29 ft·lb	p. 45
Engine lower bracket and engine	66 N·m	6.6 kgf·m · 48 ft·lb	p. 45
Engine and frame	66 N·m	6.6 kgf·m · 48 ft·lb	p. 45
Engine lower bracket and frame	38 N·m	3.8 kgf·m · 27 ft·lb	p. 45
Swingarm pivot shaft, engine, and frame	100 N·m	10 kgf·m · 72 ft·lb	p. 45
Rear shock absorber and frame	80 N·m	8 kgf·m · 58 ft·lb	p. 45
Rear shock absorber locknut	45 N·m	4.5 kgf·m · 32 ft·lb	p. 45
Relay arm and swingarm	55 N·m	5.5 kgf·m · 40 ft·lb	p. 45
Connecting arm and frame	55 N·m	5.5 kgf·m · 40 ft·lb	p. 45
Relay arm and rear shock absorber	43 N·m	4.3 kgf·m · 31 ft·lb	p. 45
Relay arm and connecting arm	55 N·m	5.5 kgf·m · 40 ft·lb	p. 45
Hub, brake caliper bracket, and swingarm	85 N·m	8.5 kgf·m · 61 ft·lb	p. 45
Drive chain adjusting bolt and locknut	16 N·m	1.6 kgf·m · 11 ft·lb	p. 45
Front shock absorber and frame	45 N·m	4.5 kgf·m · 32 ft·lb	p. 45
Front shock absorber locknut	30 N·m	3 kgf·m · 22 ft·lb	p. 45
Upper front arm and frame	38 N·m	3.8 kgf·m · 27 ft·lb	p. 45
Lower front arm and frame	55 N·m	5.5 kgf·m · 40 ft·lb	p. 45
Steering stem, pitman arm, and frame	180 N·m	18 kgf·m · 130 ft·lb	p. 45
Steering stem bushing and frame	23 N·m	2.3 kgf·m · 17 ft·lb	p. 45
Steering stem and handlebar holder	23 N·m	2.3 kgf·m · 17 ft·lb	p. 45
Tie-rod end and locknut	15 N·m	1.5 kgf·m · 11 ft·lb	p. 45
Steering knuckle	23 N·m	2.3 kgf·m · 17 ft·lb	p. 45
Steering knuckle and front wheel hub	70 N·m	7 kgf·m · 50 ft·lb	p. 45
Steering knuckle and front arm	25 N·m	2.5 kgf·m · 18 ft·lb	p. 45
Steering knuckle and tie-rod ball joint	25 N·m	2.5 kgf·m · 18 ft·lb	p. 45
Pitman arm and tie-rod ball joint	25 N·m	2.5 kgf·m · 18 ft·lb	p. 45
Frame and bearing retainer	65 N·m	6.5 kgf·m · 47 ft·lb	p. 45
Fuel tank and fuel cock	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 45
Fuel tank and frame	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 45
Front wheel and front wheel hub	45 N·m	4.5 kgf·m · 32 ft·lb	p. 45
Rear axle and rear wheel hub	120 N·m	12 kgf·m · 85 ft·lb	p. 45
Rear wheel and rear wheel hub	45 N·m	4.5 kgf·m · 32 ft·lb	p. 45
Driven sprocket and sprocket bracket	55 N·m	5.5 kgf·m · 40 ft·lb	p. 45
Front brake pipe nut	19 N·m	1.9 kgf·m · 13 ft·lb	p. 45
Front brake master cylinder and handlebar	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 45
Parking brake lever and clutch lever	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 45
Brake hose joint and frame	10 N·m	1 kgf·m · 7.2 ft·lb	p. 46
Bleed screw	6 N·m	0.6 kgf·m · 4.3 ft·lb	p. 46
Front brake pad retaining bolt	18 N·m	1.8 kgf·m · 13 ft·lb	p. 46
Front brake caliper and brake hose	27 N·m	2.7 kgf·m · 19 ft·lb	p. 46
Rear brake caliper retaining bolt	23 N·m	2.3 kgf·m · 17 ft·lb	p. 46
Rear axle ring nut	100 N·m	10 kgf·m · 72 ft·lb	p. 46
Rear axle ring nut set bolt	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 46
Rear brake pad retaining bolt	18 N·m	1.8 kgf·m · 13 ft·lb	p. 46
Rear brake caliper and brake hose	30 N·m	3 kgf·m · 22 ft·lb	p. 46
Rear brake master cylinder and frame	20 N·m	2 kgf·m · 14 ft·lb	p. 46
Parking brake adjusting bolt and locknut	16 N·m	1.6 kgf·m · 11 ft·lb	p. 46
Rear brake fluid reservoir and bracket	4 N·m	0.4 kgf·m · 2.9 ft·lb	p. 46
Side cover, rear fender, and frame	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 46
Footrest and frame	65 N·m	6.5 kgf·m · 48 ft·lb	p. 46
Battery holding bracket and frame	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 46
Air filter case and frame	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 46
Headlight and frame	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 46
Tail/brake light bracket and frame	7 N·m	0.7 kgf·m · 5.1 ft·lb	p. 46

Capacities

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Fuel tank	10 L		p. 27
Coolant	0.29 L		p. 35

Spark plugs

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
CR8E	—		p. 28
M10S	—		p. 42

Service intervals

Values extracted from the document text. Check against the original before service work.

Item	Value	Also	PDF page
Coolant change	24 months		p. 72

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