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Yamaha KODIAK 450 2021, Owner'S Manual, Page: 117 / 172

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Yamaha KODIAK 450 2021 Owner'S Manual Download Page 117

9-27

9

EBU38831

Changing the differential gear oil

The differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil must be
changed as follows at the intervals specified in the
periodic maintenance chart.

For non-differential gear lock models

For differential gear lock models

1. Differential gear oil filler bolt
2. Gasket

2

1

Recommended differential gear oil:

Yamaha Friction Modified Shaft Drive Gear 
Oil or SAE 80 API GL-4 Hypoid gear oil

Oil quantity:

0.35 L (0.37 US qt, 0.31 Imp.qt)

1. Differential gear oil filler bolt
2. Gasket

Recommended differential gear oil:

Yamaha Friction Modified Shaft Drive Gear 
Oil or SAE 80 API GL-4 Hypoid gear oil

Oil quantity:

0.23 L (0.24 US qt, 0.20 Imp.qt)

2

1

UBEY60E0.book  Page 27  Monday, July 27, 2020  10:46 AM

Summary of Contents for KODIAK 450 2021

Page 1: ...ANUAL DEL PROPIETARIO BEY 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 AT...

Page 2: ...DIC183 Original instructions Notice originale Manual original PRINTED IN USA 2020 08 0 3 1 CR E F S...

Page 3: ...EFULLY It contains important safety information WARNING OWNER S MANUAL YFM450FWB YFM450FWBD This ATV should not be ridden by anyone under 16 years of age BEY F8199 60 E0 UBEY60E0 book Page 1 Monday Ju...

Page 4: ...The Netherlands Signature Shin Yokomizo Date of Issue to which this declaration applies conforms to the essential health and safety requirements of Directive 2006 42 EC To effect correct application o...

Page 5: ...des important safety information It provides information about special tech niques and skills necessary to ride the ATV It also includes basic maintenance and inspection proce dures If you have any qu...

Page 6: ...he figures shown in this manual This is the 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...

Page 7: ...r motorway Please check your local riding laws and regulations before operating this ATV EBU17411 YFM450FWB YFM450FWBD OWNER S MANUAL 2021 by Yamaha Motor Co Ltd 1st edition March 2020 All rights rese...

Page 8: ...13 Speed limiter 5 13 Front brake lever 5 14 Brake pedal and rear brake lever 5 14 Drive select lever 5 15 Fuel tank cap 5 16 Fuel 5 17 Seat 5 18 Storage compartment 5 19 Front carrier 5 20 Rear carri...

Page 9: ...ntrol system 9 3 Periodic maintenance chart General maintenance and lubrication 9 5 Removing and installing panels 9 10 Checking the spark plug 9 17 Engine oil and oil filter cartridge 9 19 Why Yamalu...

Page 10: ...uckle pivots 9 52 Lubricating the steering shaft 9 52 Battery 9 53 Replacing a fuse 9 57 Replacing a headlight bulb 9 59 Adjusting a headlight beam 9 62 Replacing the brake tail light bulb 9 63 Removi...

Page 11: ...IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26032 Vehicle identification number The vehicle identification number is stamped into the frame This 17 digit number is used to identify your individua...

Page 12: ...specific model can be identified by checking the model type code found on the model label 1 Model label 1 Model type code 2 Production code 3 Color code 1 1 3 2 UBEY60E0 book Page 2 Monday July 27 202...

Page 13: ...all of the labels 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...

Page 14: ...2 2 2 1 4 2 3 8 9 10 11 12 5 6 6 6 7 6 14 13 UBEY60E0 book Page 2 Monday July 27 2020 10 46 AM...

Page 15: ...7S F817R 10 80 kg 176 lbs 1P0 F816P 20 YAMAHA BB5 F816M M0 35 0 kPa 0 35 kgf cm 5 0 psi 30 0 kPa 0 30 kgf cm 4 4 psi 50 0 kPa 0 50 kgf cm 7 3 psi 50 0 kPa 0 50 kgf cm 7 3 psi 1 2 3 4 UBEY60E0 book Pag...

Page 16: ...2 4 2 5880 N 600 kgf 1322 lbf 147 N 15 kgf 33 lbf 37S F817S 00 1P0 F816R 00 BB5 F2259 20 B16 F811S 01 8 5 6 7 UBEY60E0 book Page 4 Monday July 27 2020 10 46 AM...

Page 17: ...2 5 2 YAMAHA 1HP F811R 00 E10 E5 B4F F817K 00 9 10 11 UBEY60E0 book Page 5 Monday July 27 2020 10 46 AM...

Page 18: ...F155A 40 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM450FWBD 20 0 kW 308 kg 2020 B5R F155A 20 YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA JAPAN YFM450FWBD 20 0 kW 313 kg 2020 B5R F155A 30 BAS F8459 00...

Page 19: ...ctive gear Use from 16 years old Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER use on paved roads NEVER carry passengers NEVER use with drugs...

Page 20: ...an cause loss of control Loss of control can result in severe injury or death This pictogram shows the loading limits and or maximum load capacity for this ATV Follow all load limits and other loading...

Page 21: ...ld under 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...

Page 22: ...ing to turn at faster speeds and never turn at excessive speeds Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Alwa...

Page 23: ...as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Never operate an ATV in fast flowing water or in water deeper than that recommended in this m...

Page 24: ...sary If you can physically operate your vehicle inspect your vehicle If the vehicle is in safe operating con dition and you can safely operate it restart it and ride gently back to camp or other known...

Page 25: ...ange any of the vehicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries re lated to changes in the vehicle Keep...

Page 26: ...d you can quickly be overcome and unable to save yourself Also deadly levels of carbon monoxide can linger for hours or days in en closed or poorly ventilated areas If you experi ence any symptoms of...

Page 27: ...tridge 8 Coolant reservoir 9 V belt cooling duct check hose 1 2 3 4 5 9 7 8 6 1 Spark arrester 2 Storage compartment and tool kit 3 Fuel tank cap 4 Spark plug 5 Auxiliary DC jack 6 Front shock absorbe...

Page 28: ...r switches 3 Winch switch 4 Horn switch 5 Drive select lever 6 Display unit 7 Front brake fluid reservoir 8 On Command four wheel drive switch 9 Throttle lever 10 Front brake lever 11 Main switch 1 2...

Page 29: ...ctrical systems are off The key can be re moved EBU26699 Indicator lights and warning lights For non differential gear lock models OFF ON 1 Neutral indicator light N 2 Reverse indicator light R 3 Park...

Page 30: ...down for about 10 minutes The electrical circuit of the warning light can be checked by turning the key to on The warning light should come on for a few seconds and then go off If the warning light do...

Page 31: ...ystem For differential gear lock models This warning light comes on or flashes if a problem is detected in the electrical circuit monitoring the engine When this occurs the display will indicate an er...

Page 32: ...ock indicator light equipped models This indicator light comes on when the drivetrain is set to 4WD with the differential gear locked TIP When using the On Command differential gear lock switch the in...

Page 33: ...auge disappear from F full towards E empty as the fuel level decreases When the last segment starts flashing refuel as soon as possible TIP This fuel gauge is equipped with a self diagnostic system If...

Page 34: ...t the service tripmeter push the select but ton SEL for one second TIP The service tripmeter will reset and continue counting after 9999 9 is reached Hour meter The hour meter shows the total time the...

Page 35: ...tes an error code note the code number and have a Yamaha dealer check the vehicle NOTICE ECB01181 To prevent engine damage be sure to consult a Yamaha dealer as soon as possible if this oc curs EBU180...

Page 36: ...ential gear lock models 1 Light switch OFF 2 Start switch 3 Engine stop switch 4 Override switch OVERRIDE equipped models 5 Horn switch 6 Winch switch OUT IN 4 3 2 5 1 6 1 On Command drive switch 2WD...

Page 37: ...and right headlights low beams and the taillight Set the switch to to turn on the left and right head lights high beams the handlebar mounted light equipped models and the taillight Set the switch to...

Page 38: ...ores the speed limiting function While the override switch is pushed the segments of the speedometer digits will appear as shown in the figure TIP If the digits of the speedometer appear as shown when...

Page 39: ...four wheel drive or vice versa while moving may cause the ATV to unexpectedly handle differently This could distract the oper ator and increase the risk of losing control and of causing an accident E...

Page 40: ...ng the handlebar back and forth will help the differen tial gear lock to engage or disengage Riding before the differential gear is properly en gaged or disengaged e g when the indicator light is flas...

Page 41: ...ion when released Always check that the throttle le ver returns normally before starting the engine EBU18325 Speed limiter The speed limiter keeps the throttle from fully opening even when the throttl...

Page 42: ...t of the speed limiter and throttle could cause throttle cable damage or improper throttle operation You could lose control resulting in an accident EWB00242 3 Tighten the locknut EBU18393 Front brake...

Page 43: ...the brake pedal or pull the brake lever toward the handlebar grip EBU18614 Drive select lever The drive select lever is used to shift the transmis sion into the low range high range neutral re verse a...

Page 44: ...l while smoking or while in the vicinity of sparks open flames or other sources of ignition such as the pilot lights of water heat ers and clothes dryers 2 Do not overfill the fuel tank When refueling...

Page 45: ...Handle gasoline with care Never siphon gasoline by mouth If you should swallow some gasoline or inhale a lot of gasoline vapor or get some gasoline in your eyes see your doctor immediately If gasolin...

Page 46: ...ntent does not exceed 10 E10 Gas oline containing methanol is not recommended because it can cause damage to the fuel system or vehicle performance problems NOTICE ECB00071 Use only unleaded gasoline...

Page 47: ...ools in the storage compartment If they must be stored wrap them in appropriate cushion material to prevent damaging the stor age compartment The storage compartment is located under the seat See page...

Page 48: ...reload can be adjusted to suit the rid er s weight and the riding conditions WARNING EWB00401 Always adjust the shock absorber assemblies on the left and right side to the same setting Uneven adjustme...

Page 49: ...pecial wrench can be obtained at a Yamaha dealer to make this adjustment 1 Spring preload adjusting ring 2 Position indicator 1 2 3 4 5 a b 1 2 1 Special wrench 1 UBEY60E0 book Page 21 Monday July 27...

Page 50: ...e between the winch and pulled object or the winch and anchor point Do not use the winch unless all bystanders are Front spring preload setting Minimum soft 1 Standard 2 Maximum hard 5 Rear spring pre...

Page 51: ...s battery even when the engine is idling Allow the winch mo tor to cool and the battery to recharge between uses EBU28972 Trailer hitch equipped models This ATV is equipped with a 5 cm 2 in trailer h...

Page 52: ...ter can be used when the main switch is turned on However to prevent bat tery drain use when the engine is running and the headlights are turned off 1 Start the engine 2 Turn the headlights off 3 Make...

Page 53: ...f or with the headlights on the battery may dis charge to the point that the engine will not start Do not use an automotive cigarette lighter or other accessory with a plug that gets hot The DC jack m...

Page 54: ...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 55: ...les Make sure that operation is smooth Lubricate if necessary 9 49 Wheels and tires Check wheel condition and replace if damaged Check tire condition and tread depth Replace if necessary Check air pre...

Page 56: ...necessary See page 9 29 TIP The coolant level must be checked on a cold en gine since the level varies with engine tempera ture EBU28533 Front and rear brakes Brake levers and brake pedal Check that t...

Page 57: ...smoothly and spring back to the idle position when released Have a Yamaha dealer correct if necessary EBU38663 Tires Check and adjust the tire pressure before each ride Check tires for wear and damage...

Page 58: ...4 4 psi Front Minimum 32 0 kPa 0 320 kgf cm 4 6 psi Rear Minimum 27 0 kPa 0 270 kgf cm 4 0 psi With cargo or trailer Front Recommended 50 0 kPa 0 500 kgf cm 7 3 psi Rear Recommended 50 0 kPa 0 500 kg...

Page 59: ...xtensive tests only the tires list ed below are approved for this model by Yamaha WARNING EWB02552 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent 1 Ti...

Page 60: ...f handling braking and comfort Other tires rims sizes and combinations may not be appropriate EBU19841 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened EBU19851 Instru...

Page 61: ...mmended to shift into neutral or park and apply the rear brake when starting the engine NOTICE ECB00151 See the Engine break in section on page 7 4 prior to operating the engine for the first time To...

Page 62: ...n 10 seconds on any single attempt NOTICE ECB00164 For maximum engine life never accelerate hard when the engine is cold EBU36230 Operating the drive select lever and driving in reverse NOTICE ECB0333...

Page 63: ...ple or ob stacles behind you When it is safe to proceed go slowly 1 Bring the ATV to a complete stop 2 Apply the brake pedal 3 Shift from neutral to reverse or from reverse to park and vice versa by m...

Page 64: ...r the first 240 km 150 mi or 20 hours During this period the various parts in the engine wear and polish themselves to the cor rect operating clearances Avoid prolonged full throttle operation or any...

Page 65: ...applying the brakes 2 Stop the engine 3 With the brake pedal applied shift the drive select lever to the park position EBU20911 Accessories and loading EBU20922 Genuine Yamaha Accessories Choosing acc...

Page 66: ...while 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 he...

Page 67: ...d does not interfere with 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 var...

Page 68: ...8 1 8 EBU21142 RIDING YOUR ATV UBEY60E0 book Page 1 Monday July 27 2020 10 46 AM...

Page 69: ...3 6 Also read all warn ing and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01382 Do not operate this ATV or allow anyone else to operate...

Page 70: ...t are not recommended for their age can lead to severe injury or death of the child This ATV is designed to carry the operator and cargo only passengers prohibited The long seat is to allow the operat...

Page 71: ...Operating without an ap proved motorcycle helmet increases your chances of a severe head injury or death in the event of an accident EWB01412 Wear eye protection when operating your ATV to reduce the...

Page 72: ...ach time you use it to make sure the ATV is in safe operating condition Perform the pre operation checks listed on page 6 1 Always follow the inspection and mainte nance procedures and schedules descr...

Page 73: ...centered 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...

Page 74: ...your balance and fall off of the ATV If you remove a foot from a footboard your foot or leg may come into con tact with the rear wheels which could injure you or cause an accident EWB01472 Avoid whee...

Page 75: ...he 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 76: ...aces 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 EWB01512 While r...

Page 77: ...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 unfamiliar t...

Page 78: ...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 cau tion flag on the AT...

Page 79: ...release the throttle and apply the brakes smoothly and evenly Improper use of the brakes can cause the tires to lose traction reducing control and increasing the possibility of an accident NOTICE ECB0...

Page 80: ...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 81: ...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 82: ...you 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...

Page 83: ...xtremely 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 c...

Page 84: ...her the front or rear brake because 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 shar...

Page 85: ...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 you...

Page 86: ...ide your ATV without verifying that you have regained proper braking ability WARNING Wet brakes may have reduced stopping ability which could cause loss of control EWB02622 After riding your ATV in wa...

Page 87: ...arge rocks or fallen trees When you go over obstacles always follow proper procedures as described in the Owner s Manual Riding over rough terrain should be done with caution Look out for obstacles wh...

Page 88: ...slowly and be very cautious in order to re duce the chance of skidding or sliding out of control Care should be used when riding on loose or slip pery surfaces since the ATV may slide If unex pected a...

Page 89: ...Position your weight over the front wheels for better control See page 8 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If necessary gradually let off the throttl...

Page 90: ...you discover that the ATV is going to tip over dismount on the uphill side See page 8 17 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles...

Page 91: ...urn 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 fir...

Page 92: ...in the tool kit are intended to assist you in the performance of preventive maintenance and minor repairs However additional tools such as a torque wrench are necessary to perform cer tain maintenanc...

Page 93: ...ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320 1 Fuel line Check fuel hoses for cracks...

Page 94: ...lve and hose for damage Check condition and clean or replace if neces sary NO ITEM CHECK OR MAINTENANCE JOB INITIAL EVERY Whichev er comes first month 1 3 6 6 12 km mi 240 150 1300 800 2500 1600 2500...

Page 95: ...cial 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 240 150 1300 800 2500 1600 2500 1600 5000 3200 hours 20 80 160 160 320...

Page 96: ...ssary 8 Tires Check tread depth and for damage and replace if necessary Check air pressure and balance and correct if necessary 9 Wheel hub bearings Check for looseness or damage and replace if necess...

Page 97: ...17 Steering system Check operation and repair or replace if dam aged Check toe in and adjust if necessary 18 Engine mounts Check for cracks or other damage and replace if necessary 19 Axle boots Chec...

Page 98: ...es Lubricate 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 correct if...

Page 99: ...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 chan...

Page 100: ...e removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a panel needs to be removed and installed 1 Panel A 2 Panel B 2 1 1 Panel C 2 Panel D 3 Pane...

Page 101: ...sure that no foreign material enters the fuel tank ECB01052 To remove the panel 1 Remove the seat See page 5 18 2 Remove the bolts and quick fasteners 3 Remove the fuel tank cap and then pull the pan...

Page 102: ...he bolts and quick fasteners 4 Install the seat Panels B and C When removing or installing panel C the drive se lect lever must be moved out of the park position Apply the brake pedal and move the dri...

Page 103: ...the bolts and then take the panel off To install the panel Place the panel in the original position and then install the bolts Panel E To remove the panel Pull outward on the areas shown to release th...

Page 104: ...place Panel F To remove the panel 1 Remove panels B and C 2 Remove the cover For handlebar mounted light equipped models Remove the handlebar mounted light cover See page 9 59 For non equipped models...

Page 105: ...e the carrier bolts under the fenders and then take the carrier off 1 Handlebar cover 1 Carrier bolt top 2 Panel F 1 1 1 1 2 1 Carrier bolt under the fenders 1 Carrier bolt under the fenders 1 1 UBEY6...

Page 106: ...ick fasteners 3 Place the carrier in the original position and then install the carrier bolts under the fenders 4 Install the carrier top bolts and then tighten all bolts to the specified torques 1 Qu...

Page 107: ...o check Since heat and deposits will cause any spark plug to slowly erode the spark plug should be removed and checked in ac cordance with the periodic maintenance chart In addition the condition of t...

Page 108: ...spark plug for electrode erosion and excessive carbon or other deposits and replace it if necessary 3 Measure the spark plug gap with a wire thick ness gauge and if necessary adjust the gap to specifi...

Page 109: ...fied in the periodic maintenance chart To check the engine oil level 1 Park the ATV on a level surface 2 Remove panel E See page 9 10 3 Check the engine oil level on a cold engine TIP If the engine wa...

Page 110: ...cessary 8 Install the engine oil filler cap and the panel To change the engine oil and replace the oil fil ter cartridge 1 Park the ATV on a level surface 2 Remove panel E See page 9 10 3 Start the en...

Page 111: ...is not be ing replaced 6 Remove panels C and D See page 9 10 7 Remove the oil filter cartridge with an oil filter wrench 1 Engine oil drain bolt 2 Gasket 1 2 1 Oil filter cartridge 1 Oil filter wrench...

Page 112: ...ge with an oil fil ter wrench and then tighten it to the specified torque 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 bo...

Page 113: ...e engine off wait at least ten minutes and then check the oil level and correct it if necessary 16 Install panel E EBU38620 Why Yamalube YAMALUBE oil is a Genuine YAMAHA Part born of the engineers pas...

Page 114: ...a level surface 2 Remove the final gear oil filler bolt and its gas ket and then check the oil level in the final gear case The oil level should be at the brim of the filler hole 3 If the oil is belo...

Page 115: ...drain the oil from the final gear case 5 Install the drain bolt and its new gasket and then tighten the bolt to the specified torque 6 Refill with the recommended final gear oil to the brim of the fi...

Page 116: ...ck the final gear case for oil leakage If oil is leaking check for the cause 10 Install the final gear case guard by installing the bolts and then tightening them to the specified torque 1 Final gear...

Page 117: ...differential gear lock models For differential gear lock models 1 Differential gear oil filler bolt 2 Gasket 2 1 Recommended differential gear oil Yamaha Friction Modified Shaft Drive Gear Oil or SAE...

Page 118: ...ity when filling Overfilling will cause the oil to seep out of the breather hose during and af ter riding The differential gear case capacity is greater than the recommended oil quantity therefore the...

Page 119: ...vailable soft water may be used for refilling Do not use hard water or salt water since they are harmful to the en gine EBU2712A To check the coolant level 1 Park the ATV on a level surface TIP The co...

Page 120: ...en install the panel NOTICE If coolant is not available use distilled water or soft tap water in stead Do not use hard water or salt water since they are harmful to the engine If wa ter has been used...

Page 121: ...ce a thick rag over the cap when opening Allow any remaining pressure to escape before completely removing the cap 1 Park the ATV on a level surface 2 Remove the front carrier and panel F See page 9 1...

Page 122: ...water 9 Install the coolant drain bolt and its new gas ket and then tighten the bolt to the specified torque 10 Connect the coolant reservoir hose 11 Pour the recommended coolant into the res ervoir t...

Page 123: ...peration When servicing the air filter elements check the air filter case inlet for obstruc tions Check the air filter case rubber joint to the throttle body and the rubber joint manifold fittings for...

Page 124: ...main air filter assembly and sub air filter element 1 Air filter case cover holder 2 Air filter case cover 1 1 2 1 Main air filter assembly 1 Sub air filter element 1 1 UBEY60E0 book Page 34 Monday J...

Page 125: ...1943 7 Squeeze out the excess moisture and let dry NOTICE Do not twist the sponge material when squeezing it ECB00442 8 Check the air filter elements sponge material for damage replace if necessary 9...

Page 126: ...rformance and possible overheating ECB00763 13 Install the seat EBU28905 Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be fore cleaning the spark arrester WARNING EWB02342...

Page 127: ...t cooling duct check hose If dust or water collects in the V belt cooling duct check hose remove the hose and clean it EBU23932 V belt case drain plug After riding in water deep enough to allow it to...

Page 128: ...le lever free play For non differential gear lock models 1 V belt case drain plug 1 1 Throttle lever free play 2 Rubber cover 3 Locknut 4 Throttle lever free play adjusting bolt 2 4 3 1 UBEY60E0 book...

Page 129: ...resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the inter vals specified in the periodic maintenan...

Page 130: ...dam aged or if the lining thickness reaches the specified limit have a Yamaha dealer replace the brake pads as a set TIP The wheels need to be removed to check the brake pads See page 9 63 EBU30322 Re...

Page 131: ...ve a Yamaha dealer check the brake sys tem before further riding WARNING EWB02721 Improper maintenance can result in loss of braking ability Observe these precautions Insufficient brake fluid may allo...

Page 132: ...ed at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hoses Replace every four years EBU24396 Checking the front brake lever free play There...

Page 133: ...e brake lever free play turn 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 ca...

Page 134: ...CE Make sure that distance B measures 22 mm 0 87 in 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 Y...

Page 135: ...ight is within the specified limits 4 Tighten the locknut 5 Install the footboard by installing the quick fasteners bolts and nuts and then tighten the bolts to the specified torques Brake pedal heigh...

Page 136: ...rder shown 1 Footboard bolt A 2 Footboard bolt B 3 Quick fastener 3 1 2 1 3 Tightening torques Footboard bolt A 4 0 N m 0 40 kgf m 3 0 lb ft Footboard bolt B 8 N m 0 8 kgf m 5 9 lb ft 1 4 3 2 5 5 UBEY...

Page 137: ...nut in direc tion a To decrease the brake pedal free play turn the adjusting nut in direction b 3 Tighten the locknut EBU24232 Axle boots The axle boots must be checked for damage at the intervals sp...

Page 138: ...uld be adjusted by a Yamaha dealer Turn the rear brake light switch adjusting nut while holding the brake light switch in place To make the brake light come on earlier turn the adjusting nut in direct...

Page 139: ...ntrols and lead to an accident or injury Always make sure all control cables work smoothly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be...

Page 140: ...ing and lubricating the brake pedal The operation of the brake pedal should be checked before each ride and the pedal pivot should be lubricated if necessary Recommended lubricant Lithium soap based g...

Page 141: ...bricating the drive shaft universal joint The drive shaft universal joint must be lubricated at the intervals specified in the periodic mainte nance chart TIP For parts equipped with a grease nipple u...

Page 142: ...aintenance chart TIP For parts equipped with a grease nipple use a grease gun EBU25096 Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha dealer at the intervals specifie...

Page 143: ...o add distilled water However the battery lead connections need to be checked and tightened and the bat tery terminals cleaned if corroded If the battery seems to have discharged recharge it as soon a...

Page 144: ...sive gases Keep sparks flame cigarettes or other sources of ignition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN To remove the battery 1 Remove the seat NO...

Page 145: ...it and then place it in a cool dry place If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00942 Always keep the battery...

Page 146: ...stalling the bolts TIP Make sure the negative battery lead is routed un derneath the battery holding plate 4 Install the seat 1 Positive battery lead red 2 Negative battery lead black 3 Guide 1 2 3 1...

Page 147: ...cking or replacing a fuse 1 Turn off all electrical systems See page 5 1 1 Fuel injection system spare fuse 2 Fuel injection system fuse 3 Main fuse 4 EPS fuse equipped models 5 Fuse box 1 2 3 4 5 1 A...

Page 148: ...lead to a fire EWB02173 4 Turn on the main switch start the engine and then turn on the circuit in question 5 If the fuse immediately blows again have a Yamaha dealer check the vehicle Specified fuses...

Page 149: ...t and right headlight bulbs 1 Remove the cover at the rear of the headlight by pulling it off 2 Remove the bulb cover by pulling it off 3 Remove the socket by pushing it in and turn ing it countercloc...

Page 150: ...e socket by pushing it in and turning it clockwise 7 Install the bulb cover and the cover at the rear of the headlight NOTICE Make sure the bulb cover is securely fitted over the sock et and seated pr...

Page 151: ...ncy of the glass luminosity of the bulb and bulb life Thoroughly clean off any dirt and fin gerprints using a cloth moistened with al cohol or thinner ECB00653 6 Install the socket by pushing it in an...

Page 152: ...NOTICE ECB00691 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 adjust...

Page 153: ...burnt out bulb by pushing it in and turning it counterclockwise 3 Insert a new bulb into the bulb holder push it in and then turn it clockwise until it stops 4 Install the bulb holder together with th...

Page 154: ...tall the wheel with the arrow mark pointing in the forward rotating direction of the wheel and then install the wheel nuts TIP For models with tapered nuts be sure to install the nuts with their taper...

Page 155: ...o a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the ATV properly Use only genuine Yamaha replacement parts Im itation parts may look like Yamaha...

Page 156: ...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 Have a Yamaha dealer check the ATV The engine does not start Chec...

Page 157: ...ended coolant as soon as possible The engine will tend to overheat if the radiator is caked with mud or if the ATV is overloaded Wait until the engine has cooled Check the coolant level in the reservo...

Page 158: ...ion dry out the linings EWB02312 NOTICE Excessive wa ter pressure may cause water seepage and deterioration of wheel bearings brakes transmission seals and electrical devices Many expensive repair bil...

Page 159: ...he following steps to protect the en gine from internal corrosion a Remove the spark plug cap and spark plug b Pour a teaspoonful of engine oil into the spark plug bore c Install the spark plug cap on...

Page 160: ...10 3 10 8 Remove the battery and fully charge it See page 9 53 UBEY60E0 book Page 3 Monday July 27 2020 10 46 AM...

Page 161: ...ght of rider cargo accessories and tongue Noise and vibration level Noise level 77 311 EEC 78 0 dB A at 3125 r min Uncertainty of measurement 3 0 dB A Vibration on seat EN1032 ISO5008 Will not exceed...

Page 162: ...dard MA Quantity Oil change 2 30 L 2 43 US qt 2 02 Imp qt With oil filter removal 2 40 L 2 54 US qt 2 11 Imp qt Final gear oil Type Yamaha Friction Modified Shaft Drive Gear Oil Quantity 0 38 L 0 40 U...

Page 163: ...7 US gal 3 1 Imp gal Fuel reserve amount 4 0 L 1 06 US gal 0 88 Imp gal Throttle body ID mark BB51 Spark plug s Manufacturer model NGK DR7EA Spark plug gap 0 6 0 7 mm 0 024 0 028 in Drivetrain Primary...

Page 164: ...f cm 6 5 psi Rear 45 0 kPa 0 450 kgf cm 6 5 psi Front wheel Rim size 12 x 6 0AT Rear wheel Rim size 12 x 7 5AT Front brake Type Hydraulic disc brake Rear brake Type Mechanical wet multiple disc brake...

Page 165: ...ght LED Differential gear lock indicator light LED YFM450FWBD EPS warning light LED YFM450FWBD Fuses Main fuse 40 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Auxiliary...

Page 166: ...or is exposed to the noise Also the permissible expo sure level can vary from country This information however will enable the user of the machine to make a better evaluation of the hazard and risk EB...

Page 167: ...ombustion engines of non road mobile machinery Your Yamaha engine was designed and tested to give an optimal blend of performance without ex cessive emissions Therefore do not attempt to alter the eng...

Page 168: ...e warning light 5 2 D Differential gear lock indicator equipped models 5 4 Differential gear oil 6 3 Differential gear oil changing 9 27 Display unit 5 4 Drive select lever 5 15 Drive select lever and...

Page 169: ...rse indicator light 5 2 Riding your ATV 8 1 S Safety information 3 1 Seat 5 18 Shock absorber assemblies adjusting the front and rear 5 20 Spark arrester cleaning 9 36 Spark plug checking 9 17 Specifi...

Page 170: ...13 3 13 Y Yamalube 9 23 UBEY60E0 book Page 3 Monday July 27 2020 10 46 AM...

Page 171: ...UBEY60E0 book Page 4 Monday July 27 2020 10 46 AM...

Page 172: ...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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