YAMAHA YFZ450S PARTS CATALOGUE 04-2

YFZ450S (5TG3) EUROPE

1C5TG-300E1

2C5TG-300E1

()

YFZ450S

PARTS CATALOGUE

1st edition, July 2003

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan.

A3

A4

FOREWORD

This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly.

1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the Parts News.

2. Abbreviations The following abbreviations are used in this Parts Catalogue.

“UR” Use specified parts number. “UN” Use as many as needed. “AP” Alternate Parts “LM” Locally Made (Parts need to be ordered locally) “F#” Frame No. (Applicable machine No.) “O/S” Over Size

3. The number of components for assembly

• Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below.

• The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit.

PART NO. DESCRIPTION Q’TY REMARKS

2F5–83310–60 FRONT FLASHER LIGHT ASSY 2

115–83311–60 .BULB (6V–18W) 1

6. The asterisk (*) before a reference number indicates modified items after the first edition.

4. Applicable colours of graphics are represented in the “REMARKS” as shown below.

PART NO. DESCRIPTION Q’TY REMARKS

2N4–24110–00–X5 FUEL TANK COMP. 2 MXR

3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR

5. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual.

A5

7. Applicable Serial No.

Engine Serial No. Frame Serial No.

8. Applicable Colour Code (The (*) mark shows Model colour.)

Abbreviation Colour Name Colour Code

DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583

FOREWORD

9. Quantity Column Information

Column No. Name Of Q’ty Column Destination

1 EUR EUROPE

A6

MODEL LABEL

(1) A label called “Model Label” is affixed in the location as indicated in (3) below.

When using this parts catalogue, please be sure to cross–reference the “model code – production code No.” in the catalogue with the “model code – production code No.” indicated on the Model Label affixed onto the product concerned.

(2) “Model Label” Indication

(3) Model Label Affixing Location

(4) Colouring Information

Model Code

5TG3

Colouring

Type Code

A 0583

Colour

Code

Colour Name

DEEP PURPLISH BLUE SOLID E DPBSE

Abbrevia-

tion

(5) Model Code – Production Code Number of Model Listed in This Parts Catalogue

Model

Code

5TG3 010 FRANCE

Production

Code No.

Country

(destination)

Model

Code

Production

Code No.

Country

(destination)

A7

ENGINE

CYLINDER ............................................................................B2

CRANKSHAFT & PISTON ....................................................B4

VALVE ...................................................................................B5

CAMSHAFT & CHAIN ...........................................................B7

WATER PUMP ......................................................................B8

RADIATOR & HOSE .............................................................B9

OIL PUMP .............................................................................B10

INTAKE .................................................................................B12

CARBURETOR .....................................................................B14

EXHAUST .............................................................................C3

CRANKCASE ........................................................................C4

CRANKCASE COVER 1 .......................................................C5

STARTER ..............................................................................C7

CLUTCH ................................................................................C8

TRANSMISSION ...................................................................C10

SHIFT CAM & FORK .............................................................C12

CHASSIS

FRAME ..................................................................................C13

FRONT FENDER ..................................................................C15

REAR FENDER .....................................................................D2

OIL TANK ..............................................................................D4

REAR ARM ...........................................................................D6

REAR SUSPENSION ............................................................D8

STEERING ............................................................................D9

FRONT SUSPENSION & WHEEL ........................................D10

FUEL TANK ...........................................................................D12

SEAT .....................................................................................D13

FRONT WHEEL .................................................................... D14

FRONT BRAKE CALIPER ....................................................D15

REAR WHEEL .......................................................................E3

REAR BRAKE CALIPER .......................................................E4

STEERING HANDLE & CABLE ............................................E5

FRONT MASTER CYLINDER ...............................................E6

STAND & FOOTREST ..........................................................E7

REAR MASTER CYLINDER .................................................E8

GUARD .................................................................................E9

GENERATOR ........................................................................E10

STARTING MOTOR ..............................................................E11

HEADLIGHT ..........................................................................E12

TAILLIGHT ............................................................................E13

CONTENTS

HANDLE SWITCH & LEVER ................................................ E14

ELECTRICAL 1 ..................................................................... E15

ELECTRICAL 2 ..................................................................... F4

EMBLEM & LABEL 1 ............................................................ F5

INDEX

NUMERICAL INDEX ............................................................. M1

FIG. 1 CYLINDER

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5TA–11102–10

5TA–11133–10

5TA–11134–10

93440–10153

90105–06027

90340–12112

91808–16023

95027–06010

90430–06014

95617–06635

90116–08018

90338–18064

95707–08500

94701–00411

CYLINDER HEAD ASSY 1

.GUIDE, VALVE 1 3

.GUIDE, VALVE 2 2

.CIRCLIP 5

.BOLT, FLANGE 10

.PLUG, STRAIGHT SCREW 1

.PIN, DOWEL 2

BOLT, FLANGE 1

GASKET 1

BOLT, STUD 2

BOLT, STUD 1

PLUG 1

NUT, FLANGE 1

PLUG, SPARK (NGK R CR8E) 1

EUR

REMARKS

B

2

16

5TA–11181–00

17

90105–104A7

18

90105–106A3

19

90201–10025

20

5TA–11191–00

21

371–11167–01

22

5TG–11167–00

23

5TA–11193–00

24

90109–066F0

25

4KG–1111G–00

26

5TG–11166–00

27

90467–14015

GASKET, CYLINDER HEAD 1 1

BOLT, FLANGE 2

WASHER, PLATE 4

COVER, CYLINDER HEAD 1 1

PIPE, BREATHER 2 1

GASKET, HEAD COVER 1 1

BOLT 2

RUBBER, MOUNT 1 2

PIPE, BREATHER 1 1

CLIP 1

FIG. 1 CYLINDER

REF. NO.

28

29

30

31

32

33

34

35

36

37

38

39

PART NO. DESCRIPTION

90445–11182

90467–11106

90501–08728

5TA–11351–00

90179–06500

93612–16254

95027–06035

5TG–11395–00

95827–06014

90109–06418

90430–06014

5TA–11311–01

HOSE (L300) 1

CLIP 2

SPRING, COMPRESSION 1

GASKET, CYLINDER 1

NUT 2

PIN, DOWEL 2

BOLT, FLANGE 1

HOLDER 1

BOLT, FLANGE 1

BOLT 1

GASKET 1

CYLINDER 1 1

EUR

REMARKS

B

3

FIG. 2 CRANKSHAFT & PISTON

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5TG–11400–00

5TG–11412–00

5TG–11422–00

5TA–11681–00

93310–63437

5TG–11651–00

93306–30633

5TA–11536–00

5TA–11455–11

5BE–11454–00

5TA–11531–01

90149–06250

93306–20335

93311–62574

90170–14171

CRANKSHAFT ASSY 1

.CRANK 1 1

.CRANK 2 1

.PIN, CRANK 1 1

.BEARING 1

.ROD, CONNECTING 1

BEARING 2

GEAR, DRIVE 1

SHAFT 1 1

.WEIGHT 1 1

.GEAR, BALANCE WEIGHT 1

.SCREW 3

BEARING 1

NUT 1

EUR

REMARKS

B

4

16

90215–14287

17

90280–03006

18

5TG–11631–00

19

5TG–11603–00

20

99009–20500

21

5TG–11633–00

22

99009–20500

WASHER, LOCK 1

KEY, WOODRUFF 1

PISTON (STD) 1

PISTON RING SET (STD) 1

CIRCLIP 1

PIN, PISTON 1

CIRCLIP 1

FIG. 3 VALVE

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

PART NO. DESCRIPTION

5TA–12111–00

5TA–12112–00

5TA–12121–00

3GM–12126–00

5TA–12113–00

5TA–12114–00

5BE–12117–00

4GY–12117–00

1AA–12118–00

1WG–12118–00

33M–12119–00

4SV–12119–00

3LD–12168–00

VALVE, INTAKE 1

VALVE, INTAKE 2 2

VALVE, EXHAUST 2

SEAT, VALVE SPRING 2 5

SPRING, VALVE INNER 3

SPRING, VALVE OUTER 2

RETAINER, VALVE SPRING 3

RETAINER, VALVE SPRING 2

COTTER, VALVE 4

COTTER, VALVE 6

SEAL, VALVE STEM 2

SEAL, VALVE STEM 3

PAD, ADJUSTING (1.20) 5 UR

EUR

REMARKS

B

5

3LD–12168–20

3LD–12168–40

3LD–12168–60

3LD–12168–80

3LD–12168–A0

3LD–12168–F0

3LD–12168–H1

3LD–12168–K1

3LD–12168–M1

3LD–12168–R1

3LD–12168–U1

3LD–12168–W1

3LD–12168–Y1

3LD–12169–11

PAD, ADJUSTING (1.25) 5 UR

PAD, ADJUSTING (1.30) 5 UR

PAD, ADJUSTING (1.35) 5 UR

PAD, ADJUSTING (1.40) 5 UR

PAD, ADJUSTING (1.45) 5 UR

PAD, ADJUSTING (1.50) 5 UR

PAD, ADJUSTING (1.55) 5 UR

PAD, ADJUSTING (1.60) 5 UR

PAD, ADJUSTING (1.65) 5 UR

PAD, ADJUSTING (1.70) 5 UR

PAD, ADJUSTING (1.75) 5 UR

PAD, ADJUSTING (1.80) 5 UR

PAD, ADJUSTING (1.85) 5 UR

PAD, ADJUSTING (1.90) 5 UR

FIG. 3 VALVE

REF. NO.

13

PART NO. DESCRIPTION

3LD–12169–31

PAD, ADJUSTING (1.95) 5 UR

EUR

REMARKS

3LD–12169–50

3LD–12169–70

3LD–12169–90

3LD–12169–E0

3LD–12169–G0

3LD–12169–J0

3LD–12169–L0

3LD–12169–N0

3LD–12169–T0

14

3FV–12153–10

PAD, ADJUSTING (2.00) 5 UR

PAD, ADJUSTING (2.05) 5 UR

PAD, ADJUSTING (2.10) 5 UR

PAD, ADJUSTING (2.15) 5 UR

PAD, ADJUSTING (2.20) 5 UR

PAD, ADJUSTING (2.25) 5 UR

PAD, ADJUSTING (2.30) 5 UR

PAD, ADJUSTING (2.35) 5 UR

PAD, ADJUSTING (2.40) 5 UR

LIFTER, VALVE 5 YELLOW

B

6

FIG. 4 CAMSHAFT & CHAIN

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

PART NO. DESCRIPTION

5TA–12170–00

5TG–12180–00

93440–41178

5BE–12241–00

94591–57118

5TA–12210–00

4FM–12213–00

95027–06025

5TA–12251–01

5TA–12252–00

5TG–12299–00

CAMSHAFT ASSY 1 1

CAMSHAFT ASSY 2 1

CIRCLIP 2

GUIDE, STOPPER 2 1

CHAIN (98XRH2010-118M) 1

TENSIONER ASSY, CAM CHAIN 1

GASKET, TENSIONER CASE 1

BOLT, FLANGE 2

DAMPER, CHAIN 1 1

DAMPER, CHAIN 2 1

BOLT, STOPPER 2

EUR

REMARKS

B

7

FIG. 5 WATER PUMP

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

PART NO. DESCRIPTION

5BE–12564–00

93210–19758

5GR–12458–00

5DJ–12451–00

90201–08512

93102–11004

93102–12106

93306–00105

5TG–12422–00

5TG–12439–00

93604–10011

90430–06014

95027–06030

PIPE, WATER 2

O-RING 2

SHAFT, IMPELLER 1

IMPELLER, WATER PUMP 1

WASHER, PLATE 1

OIL SEAL 1

OIL SEAL (SD 12-22-5 HS) 1

BEARING (B6001) 1

COVER, HOUSING 1

O-RING 1

PIN, DOWEL 2

GASKET 1

BOLT, FLANGE 4

EUR

REMARKS

B

8

FIG. 6 RADIATOR & HOSE

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5TG–12576–00

90467–23109

5TG–12481–00

93210–16500

95027–06012

5TG–12577–00

5TG–12482–00

5TG–12461–00

5TG–12405–00

5SL–12462–00

90480–15235

90209–06174

90387–060A7

90387–0714B

95807–06020

HOSE 1 1

CLIP 4

PIPE 1 1

O-RING 2

BOLT, FLANGE 2

HOSE 2 1

PIPE 2 1

RADIATOR ASSY 1

BLOWER ASSY 1

CAP, RADIATOR 1

GROMMET 4

WASHER 2

COLLAR 2

BOLT, FLANGE 2

EUR

REMARKS

B

9

16

95807–06025

17

5TG–12467–00

18

90269–07076

BOLT, FLANGE 2

COVER, RADIATOR 1

RIVET 1

FIG. 7 OIL PUMP

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5TA–13300–00

5TA–13320–00

93603–16219

93440–10153

93210–10197

99530–10114

99530–08012

90110–06058

91314–06030

5TA–13341–00

5BE–13342–00

99001–08600

99009–12400

90201–12166

5TA–13412–00

OIL PUMP ASSY 1

ROTOR ASSY 2 1

PIN, DOWEL 1

CIRCLIP 1

O-RING 1

PIN, DOWEL 1

BOLT, HEXAGON SOCKET HEAD 2

BOLT 1

GEAR, OIL PUMP IDLE 1

SHAFT, IDLE GEAR 1

CIRCLIP 1

WASHER, PLATE 1

HOUSING, STRAINER 1

EUR

REMARKS

B

10

16

5BE–13411–00

17

95027–06025

18

5TA–13440–00

19

5BE–13447–10

20

93210–47675

21

93210–07135

22

90109–065G2

23

95027–06065

24

95027–06020

25

5TG–13161–00

26

90401–10159

27

90430–10188

STRAINER, OIL 1

BOLT, FLANGE 2

ELEMENT ASSY, OIL CLEANER 1

COVER, OIL ELEMENT 1

O-RING 1

O-RING 3

BOLT 1

BOLT, FLANGE 1

PIPE, DELIVERY 1 1

BOLT, UNION 1

GASKET 2

FIG. 7 OIL PUMP

REF. NO.

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

PART NO. DESCRIPTION

90401–08038

90430–08119

5TG–13171–00

93210–07003

93210–09008

93210–12759

95027–06012

5TG–13416–00

93210–10197

99530–10114

95027–06025

5TG–13418–00

90450–22017

93210–10197

99530–10114

BOLT, UNION 2

GASKET 4

PIPE, DELIVERY 2 1

O-RING 1

BOLT, FLANGE 1

PIPE, OIL 1 1

O-RING 1

PIN, DOWEL 1

BOLT, FLANGE 1

PIPE, OIL 2 1

HOSE CLAMP ASSY 2

O-RING 1

PIN, DOWEL 1

EUR

REMARKS

B

11

43

95027–06025

BOLT, FLANGE 1

FIG. 8 INTAKE

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5TA–13597–00

90450–57004

90450–59002

90450–61001

5TG–14411–00

5TG–14453–00

5GH–14436–00

5TG–14451–00

5TG–14458–00

5TG–14479–00

5TG–14412–00

4FU–14452–00

90450–99064

5TG–1442F–00

90267–48138

JOINT, CARBURETOR 3 1

HOSE CLAMP ASSY 1

CASE, AIR CLEANER 1 1

JOINT, AIR CLEANER 1 1

HOOK 3

ELEMENT, AIR CLEANER 1

GUIDE 1

FUNNEL 1

CAP, CLEANER CASE 1 1

SEAL 1

HOSE CLAMP ASSY 1

PROTECTOR 1

RIVET, BLIND 5

EUR

REMARKS

B

12

16

90201–043H7

17

5TG–14459–00

18

4ES–14462–00

19

59V–14457–00

20

90467–22080

21

90209–06096

22

90122–06002

23

5TG–14409–00

24

31A–14435–00

25

90387–08023

26

90105–06044

27

5TG–15370–00

WASHER, PLATE 5

HOLDER, GUIDE 1

SEAL 1

CLIP 1

WASHER 1

BOLT, WING 1

DAMPER 2

GROMMET 1

COLLAR 4

BOLT, FLANGE 4

BREATHER ASSY 1

FIG. 8 INTAKE

REF. NO.

28

29

30

31

32

33

34

35

PART NO. DESCRIPTION

90105–06044

90387–07789

90201–06557

5TG–1531A–00

90501–100A0

90467–14015

5TG–1532A–00

5TG–14419–00

BOLT, FLANGE 2

COLLAR 2

WASHER, PLATE 2

HOSE, BREATHER 1 1

SPRING, COMPRESSION 1

CLIP 2

HOSE, BREATHER 2 1

PIPE 1

EUR

REMARKS

B

13

FIG. 9 CARBURETOR

REF. NO.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

PART NO. DESCRIPTION

5TG–14101–00

5JG–14959–00

91316–04012

688–14592–00

98502–04012

90202–08045

5JG–14951–00

5JG–14522–00

5JG–14388–00

3TJ–14267–40

5JG–14546–01

4FN–14997–00

3TJ–14159–40

5JG–14521–00

5JG–14275–00

CARBURETOR ASSY 1 1

.GASKET 1

.BOLT 2

.SCREW 5

.SCREW, PAN HEAD 4

.WASHER, PLATE 1

.WASHER 1

.SCREW, ADJUST 1

.VALVE, VACUUM CONTROL 1

.ROLLER 1

.VALVE, NEEDLE 1

.SEAL 1

.CLIP 1

.SCREW, ADJUST 1

.SPRING 1

EUR

REMARKS

B

14

16

5JG–14264–00

17

5JG–14947–00

18

4MX–14948–04

19

3TJ–1494F–23

20

5TA–14943–27

21

4SR–14985–00

22

676–14548–00

23

4MX–14392–00

24

633–14159–00

25

5JG–14984–00

26

3TJ–14191–40

27

3TJ–14293–40

.COLLAR 1

.NOZZLE, MAIN 1

.JET, SLOW (#42) 1

.JET (#90) 1

.JET, MAIN (#100) 1

.FLOAT 1

.PIN, FLOAT ARM 1

.VALVE, NEEDLE 1

.CLIP 1

.GASKET, FLOAT CHAMBER 1

.PLUG, DRAIN 1

.COVER 1 1

FIG. 9 CARBURETOR

REF. NO.

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

PART NO. DESCRIPTION

5JG–14940–17

3TJ–14536–40

3TJ–14933–40

6H4–14561–00

5TA–14371–00

5TA–14335–00

5TA–14997–00

5NX–14562–00

5NX–14216–00

4MX–14561–00

4MX–14115–00

3TJ–14137–40

5BE–14146–00

5JG–14346–00

5JG–14565–00

.DIAPHRAGM ASSY 1

.GASKET 2

.SPRING, DIAPHRAGM 1

.O-RING 1

.PLUNGER, STARTER 1

.SPRING, PLUNGER 1

.SEAL 1

.O-RING 2

.SCREW 1

.O-RING 1

.PLUG, SCREW 1

.CLIP 3

.PLATE 1

.SCREW 1

EUR

REMARKS

B

15

43

5JG–14531–00

44

5JG–14591–00

45

5PA–14146–00

46

5TG–8259A–00

47

5TG–85885–00

48

5TG–14916–V1

49

5TG–14923–40

50

3TJ–14160–40

51

3TJ–14562–40

52

3TJ–14952–40

53

5TG–14171–00

54

5TG–14225–00

.SPRING, ADJUST SCREW 1

.SCREW 1

.PLATE 1

.SWITCH, CARBURETOR 1

.THROTTLE SENSOR ASSY 1

.NEEDLE 1

.SCREW, PILOT 1

.COIL, SPRING 1

.O-RING 1

.WASHER 1

.PLUNGER, STARTER 1

.CAP 1

FIG. 9 CARBURETOR

REF. NO.

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

PART NO. DESCRIPTION

5TG–14591–00

5TG–14935–00

5TG–14197–00

5TG–14987–00

5TG–14417–00

5TG–14418–00

5TG–14959–00

5TG–14561–00

5TG–14255–00

5TG–14335–00

5TA–14293–00

5TA–14227–00

5TA–14239–00

5TA–14987–00

3TJ–14137–40

.SCREW 1

.SPRING 1

.PIPE 1

.HOSE 1

.COVER 1 1

.COVER 2 1

.GASKET 1

.O-RING 1

.PLATE 1

.SPRING, PLUNGER 1

COVER 1 1

GASKET 1

SEAL 1

HOSE 1

CLIP 1

EUR

REMARKS

C

2

70

5TA–14428–00

71

24W–14193–00

72

91A20–07004

73

5TG–24311–00

74

90467–12053

75

90464–13133

76

90467–10038

BOLT 2

PIPE 1

TUBE, FLEXIBLE VINYL 1

PIPE, FUEL 1 1

CLIP 1

CLAMP 1

CLIP 1