2004 Yamaha YZ450F(S) Service Manual

Technician-level documentation for the Yamaha YZ450F(S) motocross bike. Covers all maintenance, disassembly, and repair procedures for optimal performance and longevity. Part Number: 5XD-28199-80.

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Document Details

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Document Number / Seller:
31181 / Peter Grant
File Size:
20.32 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
Apr 4, 2025

Models Covered & Key Technical Specifications

2004 Yamaha YZ450F(S) (5XD-28199-80) – Service Manual

Technician-level documentation | Series Set.

  • Documented Capacity Limits: 1.2 L is the total engine oil capacity for standard operation.
  • Calibrated Play Limits: 8 mm is the standard measurement for piston skirt diameter Parameters.
  • Authorized Speed Rating: 2100 r/min signifies the maximum engine idling speed Threshold.
  • Maximum Current Rating: 0.10 Ohm is the standard resistance for the primary winding Logic.
  • System Volume: 1.2 L indicates the total coolant capacity Requirements.
  • Principal Shipping Weight: 100 kg denotes the dry weight without fuel Benchmarks.

Professional Workshop Service Manual & Technical Specifications

Essential Repair Handbook: Yamaha YZ450F(S) (2004 Edition) Manual-Ref

Model-Portfolio: YZ450F(S) (2004) // System-Coverage: Engine / Chassis Logic // Model-Portfolio: Technical-Details.

The repository is divided into chapters covering all aspects of the YZ450F(S) motocross bike.

General Information

This section details machine identification, important information, special tools, and control functions.

Specifications

This chapter provides general and maintenance specifications, including torque values, definitions of units, and lubrication diagrams.

Engine

Details engine components, including the cylinder head, valves, pistons, crankshaft, and more.

Chassis

Covers the frame, suspension, wheels, and brakes.

Electrical

Information on ignition systems, CDI units, and electrical components.

Tuning

Guidance on engine and chassis tuning for optimal performance.

Properly requiring precise torque specifications ensures proper cyclic stress resistance for all components. The manual includes torque specifications for critical components to ensure proper cyclic stress resistance.

FAQ

Check the **standard** engine oil capacity. keyboard_arrow_down

1.0 L is the standard engine oil capacity for periodic oil changes.

What does the **necessary** valve clearance adjustment require? keyboard_arrow_down

0.10 ~ 0.15 mm is the standard intake valve clearance (cold).

Reference the **recommended** brake fluid level. keyboard_arrow_down

DOT #4 is the recommended brake fluid for optimal performance and safety.

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The service manual is incredibly detailed and easy to follow. I was able to perform maintenance tasks effortlessly. Plus, the download process was smooth, and I received the link almost instantly!