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Yamaha GRIZZLY 450 2013, Owner'S Manual, Page: 138 / 174

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Yamaha GRIZZLY 450 2013 Owner'S Manual Download Page 138

8-46

8

Adjusting the brake pedal free play

The brake pedal free play should measure 20.0
mm (0.79 in). If the free play is incorrect, adjust it
as follows.

TIP

The brake lever free play and brake pedal height
must be adjusted before adjusting the brake pedal
free play.

1. Loosen the locknut.

Tightening torques:

Footboard bolt A:

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)

Footboard bolt B:

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

6

5

6

6

5

6

2

4

3

1

1. Brake pedal free play

U2LC60E0.book  Page 46  Friday, March 8, 2013  1:18 PM

Summary of Contents for GRIZZLY 450 2013

Page 1: ...AL DEL PROPIETARIO 2LC F8199 60 READ THIS MANUAL CAREFULLY It contains important safety information LIRE ATTENTIVEMENT CE MANUEL Il comprend d importantes informations de s curit LEA ESTE MANUAL ATENT...

Page 2: ...PRINTED IN USA 2013 03 0 3 1 CR E F S DIC183 Original instructions Notice originale Manual original...

Page 3: ...LLY It contains important safety information WARNING OWNER S MANUAL YFM450DE YFM450PE YFM450PHE This ATV should not be ridden by anyone under 16 years of age 2LC F8199 60 E0 U2LC60E0 book Page 1 Frida...

Page 4: ...of EEC If applicable YAMAHA MOTOR EUROPE N V Koolhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential...

Page 5: ...olhovenlaan 101 1119 NC Schiphol Rijk The Netherlands Signature Akihiro Tsuzuki Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 20...

Page 6: ...anding of the features and operation of this ATV This manual includes important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includ...

Page 7: ...safety alert symbol It is used to alert you to potential per sonal injury hazards Obey all safety messages that follow this sym bol to avoid possible injury or death A WARNING indicates a hazardous si...

Page 8: ...torway Please check your local riding laws and regulations before operating this ATV EBU17410 YFM450DE YFM450PE YFM450PHE OWNER S MANUAL 2013 by Yamaha Motor Co Ltd 1st edition February 2013 All right...

Page 9: ...13 Brake pedal and rear brake lever 4 13 Drive select lever 4 14 Fuel tank cap 4 14 Fuel 4 15 Fuel cock 4 16 Starter choke 4 18 Seat 4 18 Storage compartments 4 19 Front carrier 4 22 Rear carrier 4 2...

Page 10: ...emission control system 8 3 General maintenance and lubrication chart 8 5 Removing and installing panels 8 10 Checking the spark plug 8 14 Engine oil and oil filter cartridge 8 17 Final gear oil 8 21...

Page 11: ...t universal joint 8 50 Checking the stabilizer bushes 8 51 Lubricating the rear knuckle pivots 8 52 Lubricating the steering shaft 8 52 Battery 8 53 Replacing a fuse 8 55 Replacing a headlight bulb 8...

Page 12: ...abels on your ATV These labels contain important information for safe and proper operation Never remove any labels from your ATV If a label becomes difficult to read or comes off request a replace men...

Page 13: ...bs 25 0 kPa 0 25 kgf cm 3 6 psi 25 0 kPa 0 25 kgf cm 3 6 psi 5FU F816M M0 1P0 F816P 20 37S F817R 10 80 kg 176 lbs 5880 N 600 kgf 1322 lbf 147 N 15 kgf 33 lbf 37S F817S 00 1 3 2 4 5 U2LC60E0 book Page...

Page 14: ...1 3 1 1P0 F816R 00 YAMAHA 1HP F811R 00 6 7 8 U2LC60E0 book Page 3 Friday March 8 2013 1 18 PM...

Page 15: ...OR CO LTD 2500 SHINGAI IWATA JAPAN YFM450FWAD 19 4 kW 282 kg 2013 1CT F155A A0 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM450FWA 19 4 kW 276 kg 2013 1CU F155A 50 9 10 11 YFM450PE YFM450PHE 11 YFM...

Page 16: ...from 12 years old Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required for children under age 16 Use from 16 years old Operatin...

Page 17: ...loss of control Adjust the tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum lo...

Page 18: ...1 7 1 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN kW kg 1 2 3 4 1 2 3 4 Year of construction Model Name Max Power Mass In Running Order U2LC60E0 book Page 7 Friday March 8 2013 1 18 PM...

Page 19: ...1 8 1 For Oceania 6 1 2 3 4 5 7 8 9 U2LC60E0 book Page 8 Friday March 8 2013 1 18 PM...

Page 20: ...1 9 1 5880 N 1322 600 kgf 15 kgf 37S F151K 00 5FU F816M 20 25 kPa 3 6 psi 25 kPa 3 6 psi 22 kPa 3 2 psi 22 kPa 3 2 psi 1 3 4 5 2 U2LC60E0 book Page 9 Friday March 8 2013 1 18 PM...

Page 21: ...1 10 1 16 UNDER 1P0 F816L 00 7 6 U2LC60E0 book Page 10 Friday March 8 2013 1 18 PM...

Page 22: ...an be a fire or explosion hazard To avoid injury or death never store fuel or flammable liquids in this storage compartment Storage should not exceed 1 lb 0 5 kg 37S F151F 00 8 9 U2LC60E0 book Page 11...

Page 23: ...16 years old should never oper ate an ATV with engine size greater than 90 cc Never allow a child under age 16 to operate an ATV without adult supervision and never allow continued use of an ATV by a...

Page 24: ...ive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills as des...

Page 25: ...g water or in water deeper than that recommended in this manual Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to...

Page 26: ...nd ride gently back to camp or other known location where you can receive medical atten tion If necessary contact your riding party or local authorities to let them know where you are and what has hap...

Page 27: ...d others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following guide lines in mind as well as those provided under Loading wh...

Page 28: ...areas If you experi ence any symptoms of carbon monoxide poisoning leave the area immediately get fresh air and SEEK MEDICAL TREATMENT Do not run engine indoors Even if you try to ventilate engine ex...

Page 29: ...rtridge 10 Coolant reservoir 11 V belt cooling duct check hose 1 2 3 4 5 6 7 8 9 10 11 1 Rear shock absorber assembly spring preload adjusting ring 2 Spark arrester 3 Rear storage compartment and tool...

Page 30: ...andlebar switches 3 Starter choke 4 Horn switch 5 Drive select lever 6 Multi function display 7 Main switch 8 Auxiliary DC jack 9 Fuel tank cap 10 On Command four wheel drive differential gear lock sw...

Page 31: ...follows ON All electrical systems are supplied with power The headlights and taillight come on when the light switch is on and the engine can be started The key cannot be removed OFF All electrical s...

Page 32: ...cator light This indicator light comes on when the transmis sion is in the neutral position 1 On Command differential gear lock indicator light DIFF LOCK 2 Low range indicator light L 3 High range ind...

Page 33: ...so and allow it to cool down for about 10 minutes NOTICE ECB00010 The engine may overheat if the ATV is over loaded In this case reduce the load to spec ification Start the engine after making sure t...

Page 34: ...our wheel drive switch is set to the 4WD position The On Command differential gear lock indicator and the On Command differential gear lock indicator light DIFF LOCK come on when the On Command differ...

Page 35: ...pushing the TRIP ODO button and then push the TRIP ODO button for at least three seconds The tripmeters can be used to estimate the distance that can be traveled with a full tank of fuel This in forma...

Page 36: ...indicates the amount of fuel in the fuel tank When the needle reaches the red line re fill the tank at the first opportunity TIP If the ATV runs out of fuel move the fuel cock lever to the RES positi...

Page 37: ...e taillight Set the switch to to turn on the high beams and the taillight Set the switch to OFF to turn off all the lights NOTICE ECB00043 Do not use the headlights with the engine turned off for an e...

Page 38: ...rential gear lock and al low extra time and distance for maneuvers All wheels turn at the same speed when the dif ferential is locked so it takes more effort to turn the ATV The effort needed to turn...

Page 39: ...he 4WD position Then the four wheel drive indicator comes on in the multi function dis play To change from four wheel drive to two wheel drive stop the ATV and push the switch in to the 2WD position E...

Page 40: ...This ATV is equipped with a switch allowing you to lock the differential gear when in four wheel drive Select the appropriate switch position according to the terrain and the conditions 4WD four wheel...

Page 41: ...ential gear lock stop the ATV and push the switch to the 4WD position TIP When the switch is set to LOCK the differential gear lock indicator and indicator light will flash until the differential gear...

Page 42: ...er will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring loaded the ATV will decelerate and the engine will return to an idle any...

Page 43: ...ttle operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut EBU18391 Front brake lever The front brake lever is located on the right handle bar To apply the front bra...

Page 44: ...e and park positions See the Operating the drive select lever and driving in reverse section on page 6 3 for the drive select lever operation EBU18720 Fuel tank cap Remove the fuel tank cap by turning...

Page 45: ...le smoking or while in the vicinity of sparks open flames or other sources of ig nition such as the pilot lights of water heaters and clothes dryers 2 Do not overfill the fuel tank When refueling be s...

Page 46: ...aded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system Your Yamaha engine has been designed to use regular unleaded gasoli...

Page 47: ...o this position when the engine is not running ON With the fuel cock lever in this position fuel flows to the carburetor Turn the fuel cock lever to this position when starting the engine and riding 1...

Page 48: ...hoke Starting a cold engine requires a richer air fuel mix ture which is supplied by the starter choke Move the starter choke in direction a to turn on the starter choke Move the starter choke in dire...

Page 49: ...Storage compartments This ATV is equipped with two storage compart ments NOTICE ECB00830 Do not store metal or sharply edged objects like tools in the storage compartments If they must be stored wrap...

Page 50: ...storage compartment remove the storage compartment cover by turning it counterclockwise The rear storage compartment is located under the seat See page 4 18 1 Front storage compartment cover 1 Front...

Page 51: ...2 0 kg 4 lb for the rear storage compartment Do not exceed the maximum load of 210 0 kg 463 lb for the ATV TIP A drain plug is fitted at the bottom of the front stor age compartment and there is a che...

Page 52: ...the shock absorber assemblies on the left and right side to the same setting Uneven adjustment can cause poor handling and loss of stability which could lead to an ac cident Adjust the spring preload...

Page 53: ...hen the engine is running and the light switch is set to OFF 1 Set the light switch to OFF 2 Turn the accessory off 3 Start the engine See page 6 1 4 Open the auxiliary DC jack cap and then in sert th...

Page 54: ...ause the fuse to blow If accessories are used without the engine running or with the headlights turned on the battery will lose its charge and engine start ing may become difficult Do not use an autom...

Page 55: ...a Yamaha dealer Before using this vehicle check the following points ITEM ROUTINE PAGE Fuel Check fuel level in fuel tank and add recommended fuel if neces sary Check fuel line for leakage Correct if...

Page 56: ...er free play and adjust if necessary 5 4 8 37 Control cables Make sure that operation is smooth Lubricate if necessary 8 48 Wheels and tires Check wheel condition and replace if damaged Check tire con...

Page 57: ...8 26 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU28532 Front and rear brakes Brake levers and brake pedal Check that there is no free pla...

Page 58: ...he operation of the throttle lever It must open smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU19814 Tires Check tire pressure regularly to ma...

Page 59: ...n the tire groove decreases to 3 mm 0 12 in due to wear replace the tire Recommended tire pressure Front 25 0 kPa 0 250 kgf cm 3 6 psi Rear 25 0 kPa 0 250 kgf cm 3 6 psi Minimum tire pressure Front 22...

Page 60: ...ufacturing Corporation of America 1 Tire wear limit Front Manufacturer model YFM450DE CHENG SHIN C 828 AUS NZL YFM450DE MAXXIS MU13 EUR FRA GBR YFM450PE CHENG SHIN C 828 AUS NZL YFM450PE MAXXIS MU13 E...

Page 61: ...ng and comfort Other tires rims sizes and combinations may not be appropriate EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights an...

Page 62: ...p switch to 3 Shift the drive select lever into the neutral or park position The corresponding indicator light should come on if it does not come on have a Yamaha dealer check the electrical cir cuit...

Page 63: ...ach attempt 7 If the engine is started with the starter choke in position 1 the starter choke should be returned to position 2 to warm up the engine If the engine is started with the starter choke in...

Page 64: ...range 1 Bring the ATV to a complete stop 2 Apply the brake pedal and then shift by mov ing the drive select lever along the shift guide TIP Make sure that the drive select lever is completely shifted...

Page 65: ...reverse to park and vice versa by moving the drive select lever along the shift guide TIP When in reverse the reverse indicator light should come on If the indicator light does not come on have a Yama...

Page 66: ...nd polish themselves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in en gine overheating must be avoided 0 160 km 0 100...

Page 67: ...es 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position 4 Turn the fuel cock to OFF EBU20910 Accessories and loading EBU20921 Genuine Yamaha Accessories C...

Page 68: ...e you are riding could affect your ability to control the ATV Do not mount an accessory where it could inter fere with your ability to control the ATV Exam ples include but are not limited to a heavy...

Page 69: ...ith con trols or your ability to see where you are going Ride more slowly than you would without a load The more weight you carry the slower you should go Although conditions vary it is good practice...

Page 70: ...7 1 7 EBU21141 RIDING YOUR ATV U2LC60E0 book Page 1 Friday March 8 2013 1 18 PM...

Page 71: ...and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 6 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT...

Page 72: ...90 A child under 16 should never operate an ATV with engine size greater than 90 cc Use by chil dren of ATVs that are not recommended for their age can lead to severe injury or death of the child This...

Page 73: ...G Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01411 Wear eye protection when operating your ATV to reduce th...

Page 74: ...ach time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 5 1 Always follow the inspection and maintenance procedures and schedules descri...

Page 75: ...entered side to side and as low as possible Be sure cargo is se cured a loose load could change handling unexpectedly Make sure the load does not interfere with your control or ability to see where yo...

Page 76: ...ll off of the ATV If you remove a foot from a footboard your foot or leg may come into contact with the rear wheels which could injure you or cause an accident EWB01471 Avoid wheelies and jumping WARN...

Page 77: ...the engine area could catch fire Do not operate idle or park the ATV in dry grass or other dry ground cov er Keep the engine area free of dry grass brush or other combustible material Someone touching...

Page 78: ...faces may seriously affect handling and control of the ATV and may cause the ATV to go out of control Always avoid paved surfaces including sidewalks driveways parking lots and streets EWB01511 While...

Page 79: ...ch may cause the ATV to upset WARNING The ATV could go out of control if you do not have enough time to react to hidden rocks bumps or holes Go slowly and be extra care ful when operating on unfamilia...

Page 80: ...n flag on the ATV DO NOT use the flag pole bracket as a trailer hitch WARNING You could collide with another vehicle if operating in areas where you cannot easily be seen Mount a caution flag on the A...

Page 81: ...elease the throt tle and apply the brakes smoothly and evenly Im proper use of the brakes can cause the tires to lose traction reducing control and increasing the possi bility of an accident NOTICE EC...

Page 82: ...f your weight over the front wheels by moving forward on the seat Once you have learned this technique you should be able to perform it at higher speeds or in tighter curves Improper riding procedures...

Page 83: ...uddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill Never attempt to...

Page 84: ...u are climbing a hill and you find that you have not properly judged your ability to make it to the top you should turn the ATV around while you still have forward motion provided you have the room to...

Page 85: ...ely steep hills than on level surfaces or small hills Shift your weight backward and to the up side of the hill Never go down a hill at high speed Avoid going down a hill at an angle that would cause...

Page 86: ...ther the front or rear brake be cause the wheels on the uphill side could come off the ground Apply both the front and rear brakes gradually Whenever possible ride your ATV straight down hill Avoid sh...

Page 87: ...t may be necessary to correct the steering when riding on loose surfaces by pointing the front wheels slightly uphill When riding on slopes be sure not to make sharp turns either up or down hill If yo...

Page 88: ...have regained proper braking ability WARNING Wet brakes may have re duced stopping ability which could cause loss of control EWB02621 After riding your ATV in water be sure to drain the trapped water...

Page 89: ...7 20 7 1 Air filter case check hose 1 V belt cooling duct check hose left front side of ATV 1 Storage compartment check hose 1 V belt case drain plug U2LC60E0 book Page 20 Friday March 8 2013 1 18 PM...

Page 90: ...ATV may re sult SLIDING AND SKIDDING WARNING EWB01662 Skidding or sliding improperly may cause you to lose control of this ATV You may also re gain traction unexpectedly which may cause the ATV to ove...

Page 91: ...time skill at con trolled sliding can be developed The terrain should be chosen carefully before attempting such maneuvers since both stability and control are re duced Bear in mind that sliding mane...

Page 92: ...d If not stop dismount on the uphill side of the ATV and physically turn the ATV around If the ATV starts to slip backwards DO NOT USE THE REAR BRAKE IF THE ATV IS IN 2WD the ATV may tip over on top o...

Page 93: ...rn off the engine when performing mainte nance unless otherwise specified A running engine has moving parts that can catch on body parts or clothing and electri cal parts that can cause shocks or fire...

Page 94: ...he tools provided in the owner s tool kit are in tended to assist you in the performance of preven tive maintenance and minor repairs However additional tools such as a torque wrench may be necessary...

Page 95: ...re special tools data and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 1...

Page 96: ...ess and tighten all screw clamps and joints if necessary 7 Spark arrester Clean NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600...

Page 97: ...ta and technical skills NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 320 200 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Air filter...

Page 98: ...lace if necessary 9 V belt Check for wear cracks or other damage and re place if necessary 10 Drive shaft univer sal joint Lubricate with lithium soap based grease 11 Chassis fasteners Make sure that...

Page 99: ...other damage and replace if necessary 18 Axle boots Check for cracks or other damage and replace if necessary 19 Engine oil Change Check ATV for oil leakage and correct if neces sary 20 Engine oil fil...

Page 100: ...lace if neces sary 27 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 28 Front and rear brake switches Check operation and corr...

Page 101: ...t full throttle Hydraulic brake service Regularly check and if necessary correct the brake fluid level Every two years replace the internal components of the brake master cylinder and calipers and cha...

Page 102: ...ed in this chapter Refer to this section each time a panel needs to be removed and installed EBU30261 Panels A and C To remove a panel 1 Remove the seat See page 4 18 2 Pull outward on the areas shown...

Page 103: ...8 11 8 To install a panel 1 Place the panel in its original position 2 Install the seat U2LC60E0 book Page 11 Friday March 8 2013 1 18 PM...

Page 104: ...s 2 Remove the carrier bolts under the fenders and then take the carrier off 3 Remove the quick fastener screws and then pull the panel upward to remove it 1 Carrier bolt top 1 1 1 1 Carrier bolt unde...

Page 105: ...der the fenders 3 Install the carrier top bolts and then tighten all bolts to the specified torques Panel D To remove the panel Remove the bolts and then take the panel off 1 Quick fastener screw 2 Pa...

Page 106: ...s an important engine component which is easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in accor dance with the periodic m...

Page 107: ...lectrode of the spark plug is a medi um to light tan the ideal color when the ATV is ridden normally TIP If the spark plug shows a distinctly different color the engine could be operating improperly D...

Page 108: ...ads 2 Install the spark plug with the spark plug wrench and then tighten it to the specified torque TIP If a torque wrench is not available when installing the spark plug a good estimate of the correc...

Page 109: ...level on a cold engine TIP If the engine was started before checking the oil level be sure to warm up the engine sufficiently and then wait at least ten minutes until the oil set tles for an accurate...

Page 110: ...panel To change the engine oil with or without oil fil ter cartridge replacement 1 Place the ATV on a level surface 2 Remove panel E See page 8 10 3 Start the engine warm it up for several min utes an...

Page 111: ...age 8 10 7 Remove the oil filter cartridge with an oil filter wrench TIP An oil filter wrench is available at a nearby Yamaha dealer 8 Apply a thin coat of engine oil to the O ring of the new oil filt...

Page 112: ...ue with a torque wrench 10 Install panels D and C 11 Install the engine oil drain bolt and its new gasket and then tighten the bolt to the speci fied torque 1 O ring 1 Torque wrench Tightening torque...

Page 113: ...heck for the cause 14 Turn the engine off wait at least ten minutes and then check the oil level and correct it if necessary 15 Install panel E EBU30270 Final gear oil The final gear case must be chec...

Page 114: ...a level surface 2 Remove the engine guard and the final gear case guard by removing the bolts 3 Place an oil pan under the final gear case to collect the used oil 4 Remove the final gear oil filler b...

Page 115: ...ecommended oil is not available SAE80W 90 API GL 5 Hypoid gear oil may be used instead However when using this oil noise from the final gear case may occur when applying the rear brake 1 Final gear oi...

Page 116: ...e ATV In addition the differential gear oil level must be checked and the oil changed as follows at the in tervals specified in the periodic maintenance and lubrication chart To check the differential...

Page 117: ...ential gear oil filler bolt the differential gear oil drain bolt and their gasket to drain the oil from the differential gear case 4 Install the drain bolt and its new gasket and then tighten the bolt...

Page 118: ...eriodic maintenance and lubrication chart EBU27126 To check the coolant level 1 Place the ATV on a level surface TIP The coolant level must be checked on a cold en gine since the level varies with eng...

Page 119: ...hey are harmful to the engine If water has been used instead of coolant re place it with coolant as soon as possible otherwise the cooling system will not be protected against frost and corrosion If w...

Page 120: ...by hot fluid and steam blown out under pressure Always place a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Place the ATV on a level...

Page 121: ...the coolant thoroughly flush the cooling system with clean tap water 10 Install the coolant drain bolt and its new gas ket and then tighten the bolt to the specified torque 11 Connect the coolant res...

Page 122: ...system 17 Install the panels and the front carrier EBU23646 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrica...

Page 123: ...3 Remove the air filter case cover by unhooking the air filter case cover holders 4 Pull the air filter element out of the air filter case 1 Air filter case check hose 1 Air filter case cover holder...

Page 124: ...sponge material Never use low flash point sol vents or gasoline to clean the sponge ma terial because the engine could catch fire or explode EWB01941 7 Squeeze the excess solvent out of the sponge ma...

Page 125: ...ible engine damage Additionally operation without the air filter element will affect carburetor jetting with subsequent poor performance and possible engine overheating ECB00461 12 Install the seat TI...

Page 126: ...ester portion of the tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the tailpipe bolts and tighten them to the specified torque 1...

Page 127: ...ater collects in the V belt cooling duct check hose remove the hose and clean it EBU23931 V belt case drain plug After riding in water deep enough to allow it to en ter the V belt case remove the V be...

Page 128: ...hout sufficient technical knowl edge may result in poor performance of or damage to the engine EBU24010 Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjus...

Page 129: ...0 5 0 mm 0 12 0 20 in as shown Periodically check the throttle lever free play and if necessary adjust it as follows TIP The engine idling speed must be checked and ad justed if necessary before adju...

Page 130: ...er safety system cable stretch es with use which can result in improper function Therefore the safety system cable should be checked and adjusted by a Yamaha dealer at the intervals specified in the p...

Page 131: ...brake pads Check each front brake pad for damage and mea sure the lining thickness If a brake pad is dam aged or if the lining thickness is less than 1 0 mm 0 04 in have a Yamaha dealer replace the br...

Page 132: ...e the rubber seals may deteriorate causing leakage Refill with the same type of brake fluid Add ing a brake fluid other than DOT 4 may result in a harmful chemical reaction Be careful that water does...

Page 133: ...4394 Checking the front brake lever free play The brake lever free play must be checked at the intervals specified in the periodic maintenance and lubrication chart The brake lever should have no free...

Page 134: ...rn the adjusting bolt in direction b NOTICE Distance A must not measure more than 12 7 mm 0 50 in If distance A exceeds 12 7 mm 0 50 in the specified brake lever free play cannot be obtained therefore...

Page 135: ...n or less If distance B reaches 22 mm 0 87 in adjust the brake lever free play at the brake lever again If distance A exceeds 12 7 mm 0 50 in have a Yamaha dealer check the vehicle ECB01151 7 Tighten...

Page 136: ...e the footboard by removing the bolts and nuts 2 Loosen the locknut 1 Distance between brake pedal and footboard bracket 1 1 Footboard 2 Bolt and nut 3 Bolt 2 2 3 1 U2LC60E0 book Page 44 Friday March...

Page 137: ...nstall the footboard by installing the bolts and nuts and then tighten them to the specified torques TIP Tighten the footboard bolts in the order shown 1 Locknut 2 Adjusting bolt Tightening torque Loc...

Page 138: ...follows TIP The brake lever free play and brake pedal height must be adjusted before adjusting the brake pedal free play 1 Loosen the locknut Tightening torques Footboard bolt A 4 0 Nm 0 40 m kgf 2 9...

Page 139: ...BU24230 Axle boots The axle boots must be checked for damage at the intervals specified in the periodic maintenance and lubrication chart Check the axle boots for tears or damage If any damage is foun...

Page 140: ...n and the condition of all control ca bles should be checked before each ride and the cables and cable ends should be lubricated if nec essary If a cable is damaged or does not move smoothly have a Ya...

Page 141: ...ont and rear brake levers The operation of the front and rear brake levers should be checked before each ride and the lever pivots should be lubricated if necessary Front brake lever Rear brake lever...

Page 142: ...he periodic maintenance and lubrication chart If there is play in a wheel hub or if a wheel does not turn smoothly have a Yamaha dealer check the wheel hub bear ings EBU24972 Lubricating the drive sha...

Page 143: ...for cracks or damage at the intervals specified in the periodic maintenance and lubrication chart Have a Yamaha dealer replace the stabilizer bush es if necessary Recommended lubricant Lithium soap ba...

Page 144: ...use a grease gun EBU25092 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart TIP For...

Page 145: ...esia beaten egg or vegetable oil Call a physician immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes or ot...

Page 146: ...l damage the battery To store the battery If the ATV will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for...

Page 147: ...before the negative lead ECB01110 3 Install the battery holding plate by installing the bolts 4 Install the seat See page 4 18 EBU30800 Replacing a fuse The main fuse the EPS fuse and the fuse box ar...

Page 148: ...on fuse 3 Auxiliary DC jack fuse 4 Four wheel drive motor fuse 5 Signaling system fuse 6 Backup fuse for clock 7 Spare fuse 1 2 3 4 5 6 7 1 Main fuse 2 Fuse box 3 EPS fuse 4 Spare main fuse 1 2 3 4 U2...

Page 149: ...of the specified amperage WARNING Always use a fuse of the spec ified rating and never use a substitute ob ject in place of the proper fuse An improper fuse or a substitute object can cause damage to...

Page 150: ...ve the cover at the rear of the headlight by pulling it off 2 Remove the headlight bulb holder cover by pulling it off Specified fuses Main fuse 30 0 A Headlight fuse 15 0 A Ignition fuse 10 0 A Four...

Page 151: ...t free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and finger prints on the headlight bulb us...

Page 152: ...0690 It is advisable to have a Yamaha dealer make this adjustment To raise a headlight beam turn the headlight beam adjusting screw in direction a To lower a headlight beam turn the adjusting screw in...

Page 153: ...h the bulb by turning it counter clockwise 3 Remove the burnt out bulb by pushing it in and turning it counterclockwise 1 Tail brake light assembly 2 Nut 1 Tail brake light assembly 2 Tail brake light...

Page 154: ...heel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 3 Elevate the ATV and place a suitable stand under the frame 4 Remove the nuts from the wheel 5 Remove the wheel EBU25701 Installing a w...

Page 155: ...tapered side to wards the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Arrow mark 1 1 Tapered nut Tightening torques Front wheel nut 55 Nm 5 5 m kgf 40 ft lb...

Page 156: ...ny repair take it to a Yamaha dealer whose skilled technicians have the necessary tools expe rience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts...

Page 157: ...aha dealer check the ATV Have a Yamaha dealer check the ATV Remove the spark plug and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gap or replace the spark plug...

Page 158: ...can be temporarily used instead provided that it is changed to the rec ommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The...

Page 159: ...n dry out the linings EWB02311 NOTICE Excessive water pressure may cause water seepage and deteriora tion of wheel bearings brakes transmis sion seals and electrical devices Many expensive repair bill...

Page 160: ...available to prevent the fuel from deteriorat ing 5 Perform the following steps to protect the cyl inder piston rings etc from corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonfu...

Page 161: ...om entering it 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an exces sively cold or warm place less than 0 C 30 F or mor...

Page 162: ...el 77 311 EEC YFM450DE 78 3 dB A EUR FRA GBR YFM450PE 78 3 dB A EUR FRA GBR YFM450PHE 78 3 dB A Vibration on seat EN1032 ISO5008 YFM450DE 0 6 m s EUR FRA GBR YFM450PE 0 6 m s EUR FRA GBR YFM450PHE 0 6...

Page 163: ...system Coolant reservoir capacity up to the maximum level mark 0 25 L 0 26 US qt 0 22 Imp qt Radiator capacity including all routes 1 32 L 1 40 US qt 1 16 Imp qt Air filter Air filter element Wet ele...

Page 164: ...tube frame Caster angle 2 5 Trail 8 5 mm 0 33 in Front tire Type Tubeless Size AT25 x 8 12 Manufacturer model YFM450DE CHENG SHIN C 828 AUS NZL YFM450DE MAXXIS MU13 EUR FRA GBR YFM450PE CHENG SHIN C 8...

Page 165: ...t hand operation Specified brake fluid DOT 4 Rear brake Type Wet multiple disc brake Operation Left hand and right foot operation Front suspension Type Double wishbone Spring shock absorber type Coil...

Page 166: ...gear lock indicator LCD High range indicator light LED Low range indicator light LED Differential gear lock indicator light LED EPS warning light YFM450PE 12 V 1 7 W YFM450PHE 12 V 1 7 W Fuses Main f...

Page 167: ...rs that influence the actual level of exposure of work force include the characteristics of the work room the other sources of noise etc i e the number of machines and other adjacent process es and th...

Page 168: ...L LABEL INFORMATION EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame TIP The vehicle identification number is used to identify your ATV EBU26050 Model...

Page 169: ...11 2 11 1 Model label U2LC60E0 book Page 2 Friday March 8 2013 1 18 PM...

Page 170: ...7 Cleaning 9 1 Coolant 5 3 8 26 Coolant temperature warning light 4 3 D Differential gear oil 5 3 8 24 Drive select lever 4 14 Drive select lever and driving in reverse 6 3 Drive select lever safety...

Page 171: ...e lever pedal free play and pedal height 8 41 Rear knuckle pivots lubricating 8 52 Reverse indicator light 4 3 Riding your ATV 7 1 S Safety information 2 1 Seat 4 18 Shock absorber assemblies adjustin...

Page 172: ...Wheel removing 8 62 U2LC60E0 book Page 3 Friday March 8 2013 1 18 PM...

Page 173: ...U2LC60E0 book Page 4 Friday March 8 2013 1 18 PM...

Page 174: ...APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PAVED ROADS NEVER CARRY PASSENGERS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public...

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