Question about 2004 Yamaha YZ 450 F

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2004 yfz 450 brakes don't work

Ran over small tree the diameter of a quarter and the tree got jammed between the brake caliper and the nerf bars. after 10 minutes i got my quad free but the brakes don't work now. i bled the brake line and a little air came out but didn't fix problem. i don't think the master cylinder is bad bc the brakes worked fine before. i was going to bleed the system totally. maybe the caliper is bad. how do you check

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The caliper probably got torqued and slightly twisted by the tree. This would restrict movement of the brake pad. No movement - no brakes. Pull the caliper and look at the pad as you apply the brake. No movement of the brake pad? Replace the caliper.

Posted on Mar 11, 2009

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When I pull my clutch in on my yfz 450 it's not engaging it has a brand new cable and lever an a Henson racing clutch on it can anyone help me out here?

When you PULL the clutch lever in, it DISENGAGES the clutch separating the engine drive to the gears.

There are adjustments on the clutch bearing itself and then in the cable. The cable should have about an eighth to a quarter inch of free play at the lever.

Check out these three videos.

YFZ450 Clutch Mods - YouTube

alt="Video for clutch in on my yfz 450">? 6:59 Jan 18, 2010 - Uploaded by Tooextrememx How to improve your clutch responce on your YFZ450 with a few quick mods.

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Clutch gripping problem Or Adjustment LTZ400

Jan 18, 2016 | Motorcycles

1 Answer

How do you replace the rear brake caliper on a 2006 hd sportster

Start with a suitable container placed under the rear caliper brake line banjo fitting to catch any brake fluid that may leak out. NEVER reuse brake fluid. Use only Dot 5 Brake Fluid in a 2006 XLH motorcycle. NEXT remove the banjo bolt and both washers to detach the rear brake line from the brake caliper and throw away the washers, remove the pad pin plug, unscrew and remove the brake pad pin, remove the brake pads, unscrew and remove the caliper bolt pin, slide the brake caliper on the rear bolt pin away from the brake disc as far as possible. THEN with an open end wrench unscrew the mounting bracket bolt pin from the caliper mounting bracket and lift the brake brake caliper straight up and away from the brake disc and the caliper bracket.

FIRST apply about 0.4 g of G40M BRAKE GREASE inside the caliper bushing boot and the caliper pin boot and inside the boot lip to prevent sticking between the boots and the bolt pins and insert the mounting bracket bolt pin into the caliper bushing boot.

Before installing the caliper ensure that the retainer bracket is properly installed on the mounting bracket, then apply a small amount of LOCTITE 272 THREADLOCKER to the threads of the mounting bracket bolt pin, place the rear caliper assembly onto the mounting bracket and using an open end wrench thread the mounting bracket bolt pin into the caliper mounting bracket and tighten it to 87-130 in-lbs (9.8-14.7 Nm). THEN apply a small amount of LOCTITE 272 THREADLOCKER to the threads of the caliper bolt pin, slide the caliper bolt pin through the front mounting hole in the caliper, carefully insert the bolt pin shaft into the caliper pin boot in the mounting bracket and screw the bolt pin into caliper and tighten it to 15-18 ft-lbs (20.4-24.6 Nm).
NOTE that the brake caliper housing has a positive stop for banjo fitting and so when tightening the banjo bolt into the brake caliper you will need to rotate the banjo fitting clockwise until it contacts the positive stop.
THEN position a new washer onto each side of the hydraulic brake line banjo fitting, insert the banjo bolt through the washers and fitting into the caliper housing and tighten it to 20-25 ft-lbs (27.1-33.9 Nm). THEN insert the brake pads into the caliper with the friction material on the pad towards the brake disc and with the curved portion of the pad fitting into the recessed area of the caliper and the brake pad front mounting tab fitting into its slot in the caliper mounting bracket. THEN press the brake pads tightly up and against the brake pad spring and install the brake pad pin but if the pin does not easily fit in ensure that you are suing the correct brake pads and not two identical pads, that the brake pad spring is oriented correctly, that the brake pad front mounting tabs are properly seated in the slots in the mounting bracket and that the brake pads are correctly pushed tight up against the brake pad spring BEFORE the brake pad pin is installed. AND THEN tighten the brake pad pin to 131-173 in-lbs (14.8-19.6 Nm). THEN install the brake pad pin plug and tighten it to 18-25 in-lbs (2.0-2.9 Nm). THEN with the rear brake master cylinder reservoir in a level position verify the brake fluid level in the reservoir. If necessary and with the bike upright and not resting on its jiffy stand remove the rear brake master cylinder reservoir cap and add sufficient new D.O.T. 5 BRAKE FLUID to the reservoir to cause the fluid to reach the upper fluid level mark, but do not exceed this mark. THEN verify the proper operation of the master cylinder relief port because a plugged or otherwise blocked relief port could cause the brakes to drag or stick on. Do this by pressing against the rear brake caliper to push the caliper piston back into its bore and push brake fluid back through the master cylinder and into the reservoir. THEN pump the brake pedal until the caliper piston pushes the brake pads out against the brake disc and firm pressure is returned to the brake system.THEN turn ignition switch ON and pump the brake pedal to verify correct operation of the brake lamp and test ride the motorcycle at low speed to safely test the brake system. If the brakes feel at all soft or spongy, bleed the system until you get a firm, hard pedal and avoid making hard stops for the first 100 miles (160 km) to allow the new pads to become conditioned to the brake disc.

Replace brake pads at any time the brake pad friction material on either the front or rear caliper is worn to 0.04 in. (1.02 mm) or less above the backing plate and always replace both pads in a caliper as a set.

The minimum brake disc thickness is stamped on the side of the disc and it must be replaced if and when it is badly scored or worn past the minimum thickness. Maximum brake disc lateral runout and warpage is 0.008 in. (0.2 mm) when measured near the outside diameter.

May 21, 2014 | 2004 Harley Davidson XL 883 Sportster

1 Answer

I have a 2004 yfz 450 that wont idle, not sure why anymore

Hi, Anonymous and the usual suspects are:
1. Idle circuit and transfer ports clogged.
2. Air fuel mixture adjustment too lean.
3. Pilot jet clogged.
4. Faulty accelerator pump.
5. Float level too low.
6. Float bowl contaminated old fuel, water, dirt, rust, etc.
7. Float bowl vent or overflow tube clogged.
8. Fuel flow to carburetor restricted.
9. Intake manifold leak.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have nice a day.
mean YFZ won idle
YAMAHA YZ450F Owner Service Manual
OEM parts for Yamaha

Aug 08, 2013 | 2004 Yamaha YZ 450 F

1 Answer

Need help on to y i don't have compression for my

Check the bleed nipple is closed and that you have brake fluid in the rear brake reservoir.

Jun 20, 2013 | Motorcycles

2 Answers

Rear brakes don't work on my 2004 Sportster

Air in system push caliper piston right in & hold while bleeding

Ride Safe


Jan 22, 2012 | 2004 Harley Davidson XL 883C Sportster...

1 Answer

My rear brake dose not work. When I removed the cap on my rear master cylinder the rubber plunger or diaphram was twisted and colapsed. Would this mean it is bad. Cant race with no rear brakes help. Its a...

Thank you for contacting FixYa with your inquiry.
The Rubber Diaphragm by nature is usually somewhat collapsed and twisted looking. Unless it appears to be non functional it's probably OK. It's important to have fluid and make sure the air is out of the system. There is a bleeder screw to allow for evacuating the air out of the system. Go To: 2004 > 450 EXC-G RACING (USA) > CHASSIS > BRAKE CALIPER REAR
Also look at the repair kit Item #2 (50313081200)
You can purchase a complete repair manual from this site:
Make sure you have serviceable pads, proper KTM brake fluid, and the air is out of the system and the brake cylinder is functional and you will have brakes. There is also an accessory available the cools the fluid for the rear brakes and keeps them from fading if you ride the pedal or are constantly braking. Ask you dealer.
Let us know if we can be of further service.

Kind regards,

Jul 17, 2011 | 2004 KTM EXC 450 Racing

2 Answers

I just replaced the rear brake pads. I now need to bleed the brakes as they are now very little pedal

To bleed the brakes, follow these instruction exactly. First, depress the rear brake pedal and hold it. Open the brake bleed valve on the rear brake caliper and allow the brake fluid and air to escape. Then, close the brake bleeder valve. Then, release the brake pedal. Repeat the procedure until you get no air from the brake system. You can connect a piece of small diameter tubing to the brake bleed valve to direct the fluid to a catch container.

Good Luck

Jun 11, 2011 | Harley Davidson FLSTC Heritage Softail...

1 Answer

I am putting 12 inch handle bars on bike and wanna know what kind of brake line i need

You need to know how much taller your new bars are over you old one. If they're 4 inches higher, you need a 4 inch over length brake line. Now, if your brake line from the master cylinder on the handlebars goes to a "junction tee" located underneath the lower triple tree, you can simple replace the upper half. Usually, you don't see this unless the bike is equipped with dual discs brakes.

If you brake line is one piece all the way down to the caliper, you must replace the entire brake line. The best way to do any of this is to put the new handlebars on the bike, install the front master cylinder and use a piece of stiff wire and run a "fake" brake line down to the caliper. Then, measure the length of the "fake" brake line to get the proper length that you need.

Good Luck

Nov 21, 2010 | 2000 Harley Davidson FXD Dyna Super Glide

1 Answer

Timing on 06 yamaha yfz 450

Here is the SERVICE MANUAL for your bike.

Dec 25, 2009 | 2004 Yamaha YZ 450 F

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