Yamaha YFZ450R Owner'S Manual Download

Page: 7 / 156

Shifting ....................................................... 6-2
Engine break-in  .......................................... 6-4
Parking ....................................................... 6-4
Parking on a slope  ..................................... 6-5
Accessories and loading  ............................ 6-6

RIDING YOUR ATV ...................................... 7-1

GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND

GOOD JUDGMENT .................................. 7-2

BE CAREFUL WHERE YOU RIDE............. 7-9
TURNING YOUR ATV .............................. 7-12
CLIMBING UPHILL ................................... 7-13
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW

WATER ................................................... 7-19

RIDING OVER ROUGH TERRAIN ........... 7-20
SLIDING AND SKIDDING......................... 7-21
WHAT TO DO IF... .................................... 7-22
WHAT TO DO... ........................................ 7-22

PERIODIC MAINTENANCE AND
ADJUSTMENT ............................................... 8-1

Owner’s manual and tool kit ....................... 8-2
Periodic maintenance chart for

the emission control system ..................... 8-3

General maintenance and

lubrication chart ........................................8-5

Removing and installing the cowling and

panels .......................................................8-9

clutch levers ............................................8-41

Checking the shift pedal ...........................8-42

U18P16E0.book Page 2 Wednesday, May 11, 2011 3:49 PM

Summary of Contents for YFZ450R

Page 1: ...P 28199 16 LIT 11626 25 19 This ATV should not be ridden by anyone under 16 years of age WARNING YFZ45RB YFZ45RSEB OWNER S MANUAL READ THIS MANUAL CAREFULLY It contains important safety information DIC183 ...

Page 2: ...EBU17092 Read this manual carefully before operating this vehicle This manual should stay with this ve hicle if it is sold U18P16E0 book Page 1 Wednesday May 11 2011 3 49 PM ...

Page 3: ...ide the ATV It also includes basic maintenance and inspection proce dures If you have any questions regarding the operation or maintenance of your ATV please consult a Yamaha dealer AN IMPORTANT SAFETY MESSAGE Read this manual together with TIPS FOR THE ATV RIDER carefully and completely before operating your ATV Make sure you understand all instructions Pay close attention to the warning and noti...

Page 4: ...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 situation which if not avoided could result in death or serious injury A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property A TIP provides key infor...

Page 5: ...d regulations in effect at the time of manufacture Please check your local riding laws and regulations before operating this ATV EBU17382 YFZ45RB YFZ45RSEB OWNER S MANUAL 2011 by Yamaha Motor Corporation U S A 1st edition April 2011 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LI...

Page 6: ...dlebar switches 4 3 Throttle lever 4 4 Speed limiter 4 5 Clutch lever 4 5 Brake lever 4 6 Brake pedal 4 6 Parking brake lever 4 7 Shift pedal 4 8 Fuel tank cap 4 8 Fuel 4 9 Seat 4 11 Adjusting the front shock absorber assemblies 4 11 Adjusting the rear shock absorber assembly 4 16 Handlebar position 4 24 PRE OPERATION CHECKS 5 1 Fuel 5 4 Engine oil 5 4 Coolant 5 4 Front and rear brakes 5 4 Throttl...

Page 7: ...ing and installing the cowling and panels 8 9 Checking the spark plug 8 15 Engine oil and oil filter element 8 16 Coolant 8 22 Cleaning the air filter element 8 23 Cleaning the spark arrester 8 27 Adjusting the throttle lever free play 8 29 Valve clearance 8 30 Brakes 8 30 Checking the front and rear brake pads 8 30 Checking the brake fluid level 8 32 Changing the brake fluid 8 33 Checking the fro...

Page 8: ...b 8 48 Adjusting a headlight beam 8 50 Tail brake light 8 50 Removing a wheel 8 50 Installing a wheel 8 51 Troubleshooting 8 52 Troubleshooting charts 8 53 CLEANING AND STORAGE 9 1 Cleaning 9 1 Storage 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Identification numbers 11 1 Noise regulation 11 4 Maintenance record 11 5 YAMAHA MOTOR CORPORATION U S A ATV LIMITED WARRANTY 11 6 YAMAHA EXTENDED S...

Page 9: ...1 1 1 EBU17660 LOCATION OF THE WARNING AND SPECIFICATION LABELS 5 7 1 2 4 3 7 6 U18P16E0 book Page 1 Wednesday May 11 2011 3 49 PM ...

Page 10: ... 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 ment label from your Yamaha dealer U18P16E0 book Page 2 Wednesday May 11 2011 3 49 PM ...

Page 11: ... subject to an approved ATV action plan submitted by YAMAHA and on file with the U S Consumer Product Safety Commission Certification of Compliance YAMAHA MOTOR CORPORATION U S A 6555 Katella Avenue Cypress California 90630 5101 U S A 1 2 3 U18P16E0 book Page 3 Wednesday May 11 2011 3 49 PM ...

Page 12: ...vere injury or death Recommended Never set tire pressure below minimum It could cause the tire to dislodge from the rim LOADING Maximum weight capacity 220 lbs 100 kg Includes weight of operator cargo and accessories 5D3 2816M U0 OPERATING TIRE PRESSURE Set with tires cold Front 4 0 psi 27 5 kPa Rear 4 4 psi 30 0 kPa Minimum Front 3 6 psi 24 5 kPa Rear 4 0 psi 27 0 kPa WARNING NEVER ride as a pass...

Page 13: ...ould 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 child if he or she does not have the abilities to operate it safely Never carry a passenger on an ATV Always avoid operating an ATV on any paved surfaces including sidewalks driveways park ing lots and streets Never...

Page 14: ... described in this manual Check the ter rain carefully before you start up any hill Never climb hills with excessively slippery or loose sur faces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manual Check the terr...

Page 15: ...urfaces such as ice go slowly and be very cautious in order to re duce the chance of skidding or sliding out of con trol Never operate an ATV in fast flowing 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 let friction dry out the linings Always use...

Page 16: ...oorly ventilated 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 exhaust with fans or open windows and doors carbon monoxide can rapidly reach dangerous levels Do not run engine in poorly ventilated or par tially enclosed areas such as barns garages o...

Page 17: ...hift pedal 8 Coolant reservoir 9 Front shock absorber assembly rebound damping force adjusting screw 7 8 9 5 3 1 6 4 2 1 Spark arrester 2 Fuse 3 Rear shock absorber assembly spring preload adjusting nut 4 Rear shock absorber assembly compression damping force adjusting bolt for fast compression damping 5 Rear shock absorber assembly compression damping force adjusting screw for slow compression da...

Page 18: ...may differ slightly from the figures shown in this manual 1 Clutch lever 2 Parking brake lever 3 Handlebar switches 4 Fuel tank cap 5 Main switch 6 Front brake fluid reservoir 7 Throttle lever 8 Brake lever 2 1 3 7 6 5 8 4 U18P16E0 book Page 2 Wednesday May 11 2011 3 49 PM ...

Page 19: ...11 Main switch The positions of the main switch are as 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 systems are off The key can be re moved 1 Main switch OFF ON 1 U18P16E0 book Page 1 Wednesday May 11 2011 3 49 PM ...

Page 20: ...o on The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to on or if the warning light remains on have a Yamaha dealer check the elec trical circuit 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 that the warning...

Page 21: ...ht comes on or flashes when an electrical circuit monitoring the engine is not work ing correctly When this occurs have a Yamaha dealer check the self diagnosis system The electrical circuit of the warning light can be checked by turning the key to on The warn ing light should come on for a few seconds and then go off If the warning light does not come on initially when the key is turned to on or ...

Page 22: ... extended period of time oth erwise the battery may discharge to the point that the starter motor will not operate properly If this should happen remove the battery and recharge it See page 8 45 EBU18282 Throttle lever Once the engine is running pushing the throttle le ver will increase the engine speed Regulate the speed of the ATV by varying the throttle position Because the throttle is spring l...

Page 23: ... aged Always make sure the throttle lever free play is adjusted to 2 0 4 0 mm 0 08 0 16 in See page 8 29 WARNING Improper ad justment of the speed limiter and throttle could cause throttle cable damage or im proper throttle operation You could lose control resulting in an accident EWB00241 3 Tighten the locknut EBU18382 Clutch lever The clutch lever is located on the left handlebar and the ignitio...

Page 24: ...he distance between the brake lever and the handlebar grip hold the brake lever away from the handlebar so it does not contact the adjusting bolt loosen the locknut turn the adjust ing bolt and then tighten the locknut EBU18432 Brake pedal The brake pedal is located on the right side of the ATV To apply the rear brake push down on the brake pedal 1 Clutch lever 1 Brake lever 2 Locknut 3 Brake leve...

Page 25: ...ecially on a slope To apply the parking brake move the parking brake lever in direction a To release the parking brake move the parking brake lever in direction b 1 Brake pedal 1 1 Parking brake lever locked position 1 Parking brake lever unlocked position U18P16E0 book Page 7 Wednesday May 11 2011 3 49 PM ...

Page 26: ...you ride the ATV without re leasing the parking brake You could lose braking performance which could cause an accident You could also wear out the brakes prematurely EBU18530 Shift pedal This ATV is equipped with a constant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combina tion with the clutch when shifting EBU18720 Fuel tank cap Remove the ...

Page 27: ...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 sure to insert the pump nozzle into the fuel tank filler hole Stop filling when the fuel reach es the bottom of the filler tube Because fuel expands when it heats up heat from the en gine or the sun can c...

Page 28: ...ge 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 premium unleaded gasoline with a pump octane number R M 2 of 91 or higher or a research oc tane number of 97 or higher If knocking or ping ing occurs use a gasoline of a different brand Use of unleaded fuel will extend spark plug life and reduce maintenance c...

Page 29: ...t the rear Make sure that the seat is securely fitted EBU30050 Adjusting the front shock absorber as semblies These shock absorber assemblies are equipped with a spring preload adjusting nut a rebound damping force adjusting screw with a compres sion damping force adjusting bolt for fast com pression damping and a compression damping force adjusting screw for slow compression damp ing 1 Seat lock ...

Page 30: ...er of clicks or turns of a damping force adjusting mechanism may not ex actly match the following specifications due to small differences in production the actual number of clicks or turns always represents the entire ad justing range To obtain a precise adjustment it would be advisable to check the number of clicks or turns of each damping force adjusting mecha nism and to modify the specificatio...

Page 31: ... complete turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in 3 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00081 Spring preload setting Minimum soft Distance A 299 8 mm 11 80 in Standard Distance A 289 8 mm 11 41 in Maximum hard Distance A 279 8 mm 11 02 in 1 Distance A Tighten...

Page 32: ...compression damping force and thereby harden the compression damping turn the compression damping force adjusting bolt in direc tion a To decrease the compression damping force and thereby soften the compression damp ing turn the adjusting bolt in direction b 1 Rebound damping force adjusting screw a b 1 Rebound damping setting Minimum soft 20 click s in direction b Standard 12 click s in directio...

Page 33: ...ression damp ing turn the adjusting screw in direction b 1 Compression damping force adjusting bolt for fast compression damping Compression damping setting for fast com pression damping Minimum soft 2 turn s out from the fully turned in posi tion Standard 1 turn s out from the fully turned in posi tion Maximum hard Adjusting bolt fully turned in a b 1 1 Compression damping force adjusting screw f...

Page 34: ...610 Adjusting the rear shock absorber as sembly This shock absorber assembly is equipped with a spring preload adjusting nut a rebound damping force adjusting screw a compression damping force adjusting bolt for fast compression damp ing and a compression damping force adjusting screw for slow compression damping WARNING EWB02680 Suspension components become hot during operation Never touch the co...

Page 35: ...ng range To obtain a precise adjustment it would be advisable to check the number of clicks or turns of each damping force adjusting mecha nism and to modify the specifications as neces sary Spring preload 1 Remove the cowling See page 8 11 for YFZ45RB or 8 14 for YFZ45RSEB 2 Remove the clip from the hose holder remove the bolt and then move the blow by gas chamber away from the vehicle 3 Loosen t...

Page 36: ...e moving the bolts and collars 5 Remove the bolts and then remove the air fil ter case by disconnecting it from the air intake duct 1 Clamp screw 1 1 Bolt 2 Collar 3 Air filter case holding plate 1 1 2 3 U18P16E0 book Page 18 Wednesday May 11 2011 3 49 PM ...

Page 37: ...sen the locknut 9 Turn the spring preload adjusting nut in direc tion a to increase the spring preload and thereby harden the suspension and in direc tion b to decrease the spring preload and thereby soften the suspension 1 Air filter case 2 Bolt 1 Coupler 1 2 2 1 1 Clamp screw 2 Air intake duct 1 2 U18P16E0 book Page 19 Wednesday May 11 2011 3 49 PM ...

Page 38: ...e turn of the adjusting nut distance A is changed by 1 5 mm 0 06 in 10 Tighten the locknut to the specified torque NOTICE Always tighten the locknut against the adjusting nut and then tighten it to the specified torque ECB00081 1 Locknut 2 Spring preload adjusting nut 3 Special wrench 2 1 3 a b Spring preload setting Minimum soft Distance A 273 5 mm 10 77 in Standard Distance A 265 0 mm 10 43 in M...

Page 39: ...d torque 15 Install the air filter case holding plate by install ing the bolts and collars and then tighten the bolts to the specified torque 16 Install the blow by gas chamber by installing the bolt tighten the bolt to the specified torque and then install the clip to the hose holder 17 Install the cowling Rebound damping force Turn the rebound damping force adjusting screw in direction a to incr...

Page 40: ...n damping force adjusting bolt in direc tion a To decrease the compression damping force and thereby soften the compression damp ing turn the adjusting bolt in direction b 1 Rebound damping force adjusting screw Rebound damping setting Minimum soft 20 click s in direction b Standard 11 click s in direction b Maximum hard 1 click s in direction b With the adjusting screw fully turned in di rection ...

Page 41: ...ping setting for fast com pression damping Minimum soft 2 turn s out from the fully turned in posi tion Standard 1 turn s out from the fully turned in posi tion Maximum hard Adjusting bolt fully turned in 1 Compression damping force adjusting screw for slow compression damping Compression damping setting for slow com pression damping Minimum soft 18 click s in direction b Standard 8 click s in dir...

Page 42: ...re Do not deform or damage the cylinder in any way Cylinder damage will result in poor damping performance Do not dispose of a damaged or worn out shock absorber assembly yourself Take the shock absorber assembly to a Yamaha deal er for any service EBU29401 Handlebar position The handlebar can be adjusted to one of four posi tions to suit the rider s preference Have a Yamaha dealer adjust the posi...

Page 43: ...y the procedures provided in this manual have the vehicle inspected by 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 necessary 4 9 5 4 Engine oil Check oil level in engine oil tank and add recommended oil to spec ified level if necessary Check AT...

Page 44: ...ion and correct if necessary Lubricate cable if necessary Check lever free play and adjust if necessary 8 36 Throttle lever Make sure that operation is smooth Lubricate cable and lever hous ing if necessary Check lever free play and adjust if necessary 5 5 8 29 Control cables Make sure that operation is smooth Lubricate if necessary 8 40 Drive chain Check chain slack and adjust if necessary Check ...

Page 45: ...te lever pivoting points if necessary 8 41 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 5 7 Instruments lights and switches Check operation and correct if necessary 5 7 ITEM ROUTINE PAGE U18P16E0 book Page 3 Wednesday May 11 2011 3 49 PM ...

Page 46: ... 34 If the pedal height is incorrect have a Yamaha dealer adjust it Check the operation of the lever and pedal They should move smoothly and there should be a firm feeling when the brakes are applied If not have a Yamaha dealer check the brake system Brake fluid level Check the brake fluid level Add fluid if necessary See page 8 32 Brake fluid leakage Check to see if any brake fluid is leaking out...

Page 47: ...on of this vehicle with im proper tire pressure may cause severe injury or death from loss of control or rollover Tire pressure below the minimum specified could also cause the tire to dislodge from the rim un der severe riding conditions EWB02541 Set tire pressures to the following specifications The low pressure tire gauge is included as stan dard equipment Make two measurements of the tire pres...

Page 48: ...ubeless tires with valves WARNING EWB02551 Use of improper tires on this ATV may cause loss of control increasing your risk of an acci dent After extensive tests only the tires listed below have been approved for this model by Yamaha Motor Co Ltd 1 Low pressure tire gauge 1 1 Tire wear limit U18P16E0 book Page 6 Wednesday May 11 2011 3 49 PM ...

Page 49: ...not be appropriate EBU19840 Chassis fasteners Make sure that all nuts bolts and screws are prop erly tightened EBU19850 Instruments lights and switches Check that all instruments lights and switches are working properly Correct if necessary Front Manufacturer model DUNLOP KT352 Radial Size AT21 x 7R10 Type Tubeless Rear Manufacturer model DUNLOP KT357 Radial Size AT20 x 10R9 Type Tubeless U18P16E0...

Page 50: ...me 1 Set the parking brake 2 Turn the key to on and the engine stop switch to The following warning lights should come on for a few seconds then go off Coolant temperature warning light Fuel level warning light Engine trouble warning light NOTICE ECB00824 If a warning light does not go off see page 4 2 for the corresponding warning light circuit check To avoid possible damage do not oper ate the A...

Page 51: ...accelerate hard when the engine is cold EBU20522 Shifting This ATV has a 5 speed forward transmission The transmission allows you to control the amount of power you have available at a given speed or for starting accelerating climbing hills etc To shift into neutral release the throttle lever ap ply the clutch and then repeatedly depress the shift pedal until it stops When it stops it will be in f...

Page 52: ...ow the same procedure when shifting to the next higher gear EBU20650 To decelerate When slowing down or stopping release the throt tle and apply the brakes smoothly and evenly As you slow down shift to a lower gear Be sure that the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires to lose traction reducing con trol and increasing...

Page 53: ...ssive load on it for the first 320 km 200 mi or 20 hours The various parts in the engine wear and 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 mi or 0 10 hours Avoid prolonged operation above 1 2 throttle Vary the speed of the ATV regularly Do not ...

Page 54: ...shift into first gear stop the engine ap ply the parking brake and then block the front and rear wheels with rocks or other objects Never park the ATV on hills that are too steep to walk up easily 1 Bring the ATV to a stop by applying the front brake shift into first gear and then stop the engine 2 With the front and rear brakes applied apply the parking brake 3 Release the front and rear brakes 1...

Page 55: ...re not suitable because of poten tial safety hazards to you or others Installing after market products or having other modifications performed to your ATV that change any of the ve hicle s design or operation characteristics can put you and others at greater risk of serious injury or death You are responsible for injuries related to changes in the vehicle Keep the following in mind when considerin...

Page 56: ...in the maximum ATV load limit Load cargo on the carriers as close to the center of the ATV as possible Put cargo at the rear of the front carrier at the front of the rear carrier and center it Tie down cargo securely to the carriers Make sure cargo in the trailer cannot move around A shifting load can cause an accident Make sure the load does not interfere with con trols or your ability to see whe...

Page 57: ...6 8 6 WARNING EWB00011 Indicates a hazardous situation which if not avoided could result in death or serious injury U18P16E0 book Page 8 Wednesday May 11 2011 3 49 PM ...

Page 58: ...7 1 7 EBU21132 RIDING YOUR ATV U18P16E0 book Page 1 Wednesday May 11 2011 3 49 PM ...

Page 59: ...u have read this Owner s Manual completely and un derstand the operation of the controls Pay partic ular attention to the safety information on pages 2 1 2 4 Also read all warning and notice labels on your ATV RIDE WITH CARE AND GOOD JUDGMENT Get training if you are inexperienced WARNING EWB01381 Do not operate this ATV or allow anyone else to operate it without proper instruction The risk of an a...

Page 60: ...ed operator Not recommended for children under 16 years of age WARNING EWB01390 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 ATV is designed to carry the operator only passengers prohibited The long seat is to allow the operator to shift posi tion...

Page 61: ...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 the risk of a serious accident or injury Eye protection such as a face shield or goggles may reduce the risk of foreign material getting in your eyes and help prevent loss of vision WARNING Operating wi...

Page 62: ...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 described in the Own er s Manual WARNING Failure to inspect the ATV before operating it and to maintain it prop erly increases the possibility of an accident or equipment damage EWB01431 Speed limiter For r...

Page 63: ... control or ability to see where you are going Reduce speed and allow more room to stop A heavier vehicle takes longer to stop Avoid hills and rough terrain Choose terrain carefully Use extreme caution when towing or carrying a load on inclines Turn gradually and go slowly As originally equipped this ATV is not designed to carry cargo or tow a trailer If you choose to add ac cessories to carry car...

Page 64: ...ccident EWB02660 Avoid wheelies and jumping WARNING At tempting wheelies jumps and other stunts in creases the chance of an accident including an overturn Never attempt stunts such as wheelies or jumps Don t try to show off EWB01481 Modifications and accessories Never modify this ATV through improper installa tion or use of accessories or other modification All parts and accessories added to this ...

Page 65: ...ch the hot exhaust system Do not park the ATV in a place where others might be likely to touch it The muffler and other engine parts become ex tremely hot during operation and remain hot after the engine has stopped To reduce the risk of fire during operation or after leaving the ATV do not let brush grass and other materials collect under the vehicle near the muffler or exhaust pipe or next to ot...

Page 66: ...hicles In many states it is illegal to operate ATVs on public streets roads and highways WARNING Never operate this ATV on any pub lic street road or highway even a dirt or gravel one You could collide with another vehicle EWB01031 Know the terrain where you ride Ride cautiously in unfamiliar areas Stay alert for holes rocks or roots in the terrain and other hidden hazards which may cause the ATV ...

Page 67: ...excessively rough slippery or loose terrain could cause loss of traction or ATV control which could result in an accident including an overturn EWB01541 When riding in an area where you might not easily be seen such as desert terrain mount a caution 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 off road ar eas whe...

Page 68: ... not to accidentally move the shift pedal With the engine idling pull the clutch lever to disengage the clutch and shift into 1st gear and then release the parking brake Open the throttle gradually and at the same time re lease the clutch lever slowly Once the ATV has at tained adequate speed release the throttle lever and at the same time quickly pull in the clutch le ver and shift into 2nd gear ...

Page 69: ...ing at low speeds before attempting to turn at faster speeds Do not turn at speeds too fast for your skills or the conditions ATV could go out of control causing a collision or overturn To achieve maximum traction while riding off road the two rear wheels turn together at the same speed Therefore unless the wheel on the inside of the turn is allowed to slip or lose some traction the ATV will resis...

Page 70: ... to tip over to the outside while negotiating a turn lean more to the inside It may also be necessary to gradually let off on the throttle and steer to the out side of the turn to avoid tipping over Remember Avoid higher speeds until you are thoroughly familiar with the operation of your ATV CLIMBING UPHILL WARNING EWB01591 Climbing hills improperly can cause overturns or loss of control Use prope...

Page 71: ...ld be on the other side of the hill Never attempt to turn the ATV around on any hill until you have mastered the turning tech nique as described in the Owner s Manual on level ground Be very careful when turning on any hill Avoid crossing the side of a steep hill if pos sible When crossing the side of a hill shift your weight to the uphill side of the ATV U18P16E0 book Page 14 Wednesday May 11 201...

Page 72: ...ver possible ride straight up hills Slow down when you reach the crest of the hill if you cannot see clearly what is on the other side there could be another person an obstacle or a sharp drop off Use common sense and remember that some hills are too steep for you to climb or de scend If you are climbing a hill and you find that you have not properly judged your ability to make it to the top you s...

Page 73: ... Dismount the ATV im mediately on the uphill side or to a side if pointed straight uphill Turn the ATV around and remount following the procedure described in the Owner s Manual WARNING Stalling rolling backwards or improperly dismounting while climbing a hill could result in ATV overturning If you cannot control the ATV dismount immediately on the uphill side EWB01802 U18P16E0 book Page 16 Wednes...

Page 74: ...e wheels on the uphill side to come off the ground or cause loss of traction Gradually apply only the rear brake when going downhill When riding your ATV downhill shift your weight as far to the rear and uphill side of the ATV as pos sible Move back on the seat and sit with your arms straight Choose a low gear which will allow the en gine compression to do most of the braking for you Use caution w...

Page 75: ...requires you to properly position your weight to maintain proper balance Be sure that you have learned the basic riding skills on flat ground before attempting to cross a sloping surface Avoid slopes with slip pery surfaces or rough terrain that may upset your balance As you travel across a slope lean your body in the uphill direction It may be necessary to correct the steering when riding on loos...

Page 76: ...ATV water deeper than the depth specified in your Owner s Man ual as tires may float increasing the risk of an overturn The ATV can be used to cross slow moving shal low water of up to a maximum of 35 cm 14 in in depth Before entering the water choose your path carefully Enter where there is no sharp drop off and avoid rocks or other obstacles which may be slippery or upset the ATV Drive slowly an...

Page 77: ...e bottom of the air filter case NOTICE Undrained water can cause damage or improper opera tion ECB00841 Wash the ATV in fresh water if it has been operat ed in salt water or muddy conditions RIDING OVER ROUGH TERRAIN WARNING EWB01651 Riding improperly over obstacles could cause loss of control or a collision Before operating in a new area check for obstacles Never at tempt to ride over large obsta...

Page 78: ...nd on level smooth terrain On extremely slippery surfaces such as ice go 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 and uncorrected sliding could lead to an accident To reduce the tendency for the front wheels to slide in loose or slippery cond...

Page 79: ...f the turn Position your weight over the front wheels for better control See page 7 12 If your ATV begins to tip while turning Lean more into the turn to regain balance If nec essary gradually let off the throttle and or steer to the outside of the turn See page 7 12 If your ATV starts to slide sideways Steer in the direction of the slide if you have the room Applying the brakes or accelerating is...

Page 80: ... on the uphill side See page 7 18 If your ATV encounters shallow water Ride slowly and carefully through slow moving water watching for obstacles Be sure to let wa ter drain from the ATV and CHECK YOUR BRAKES FOR PROPER OPERATION when you come out of the water Do not continue to ride your ATV until you have regained adequate braking ability See page 7 19 WARNING EWB00011 Indicates a hazardous situ...

Page 81: ...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 fires Running the engine while servicing can lead to eye injury burns fire or carbon monoxide poisoning possibly leading to death See page 2 4 for more information about carbon monoxide WARNING EWB02690 B...

Page 82: ...ded in this manual and the 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 to perform certain maintenance work correctly TIP If you do not have the tools or experience required for a particular job have a Yamaha dealer perform it for you 1 Owner s man...

Page 83: ...uld be performed by a Yamaha dealer as they require 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 80 160 160 320 1 Fuel line Check fuel hoses for cracks or other damage and replace if necessary Replace Every 5 years 2 Spark plug Check condition and clean re...

Page 84: ...ess and tighten all screw clamps and joints if necessary 6 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 2500 1600 5000 3200 hours 20 80 160 160 320 U18P16E0 book Page 4 Wednesday May 11 2011 3 49 PM ...

Page 85: ...s 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 element Clean and replace if necessary Every 20 40 hours more often in wet or dusty areas 2 Clutch Check operation and adjust if necessary 3 Front brake Check operation and correct if necessary Check fluid level and ATV f...

Page 86: ...ary 10 Swingarm pivots Check operation and for excessive play and re place bearings if necessary Lubricate with lithium soap based grease 11 Upper and lower arm pivots Lubricate with lithium soap based grease 12 Drive chain Check chain slack and adjust if necessary Check rear wheel alignment and correct if neces sary Clean and lubricate 13 Drive chain roller Check for wear and replace if necessary...

Page 87: ...ering system Check operation and repair or replace if damaged Check toe in and adjust if necessary 19 Engine oil Change Check ATV for oil leakage and correct if neces sary 20 Engine oil filter ele ment Replace 21 Cooling system Check coolant level and ATV for coolant leakage and correct if necessary Replace coolant Every 2 years 22 Moving parts and cables Lubricate NO ITEM CHECK OR MAINTENANCE JOB...

Page 88: ... and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 23 Throttle lever Check operation Check throttle lever free play and adjust if neces sary Lubricate cable and lever housing 24 Front and rear brake switches Check operation and correct if necessary 25 Lights and switches Check operation and correct if necessary Adjust headlight beams NO ITEM CHECK OR MAI...

Page 89: ...e jobs described in this chapter Refer to this section each time a cowling or panel needs to be removed and installed EBU29538 Panel A YFZ45RB To remove the panel 1 Remove the seat See page 4 11 2 Remove the fuel tank cap by turning it coun terclockwise See page 4 8 NOTICE Make sure that no foreign material enters the fuel tank ECB01051 3 Remove the bolts 1 Panel A 2 Panel B 3 Cowling 1 2 3 1 Pane...

Page 90: ...turning it coun terclockwise 2 Place the panel in the original position and then install the quick fasteners NOTICE When installing the panel be sure not to pinch the cables or wires ECB00381 3 Install the bolts 4 Install the fuel tank cap by turning it clockwise 5 Install the seat 1 Bolt 1 Quick fastener 1 1 1 1 Projection 2 Slot 1 1 2 U18P16E0 book Page 10 Wednesday May 11 2011 3 49 PM ...

Page 91: ... 2 Pull the panel off To install a panel 1 Place the panel in the original position 2 Install panel A Cowling YFZ45RB To remove the cowling 1 Remove panels A B and C 2 Remove the bolts and then take the cowling off U18P16E0 book Page 11 Wednesday May 11 2011 3 49 PM ...

Page 92: ... A EBU29595 Panel A YFZ45RSEB To remove the panel 1 Remove the seat See page 4 11 2 Remove the fuel tank cap by turning it coun terclockwise See page 4 8 NOTICE Make sure that no foreign material enters the fuel tank ECB01051 3 Loosen the quick fasteners 1 Bolt 1 Bolt 1 1 1 1 U18P16E0 book Page 12 Wednesday May 11 2011 3 49 PM ...

Page 93: ... coun terclockwise 2 Place the panel in the original position and then install the quick fasteners NOTICE When installing the panel be sure not to pinch the cables or wires ECB00381 3 Tighten the quick fasteners 4 Install the fuel tank cap by turning it clockwise 5 Install the seat 1 Quick fastener 1 Quick fastener 1 1 1 1 Projection 2 Slot 1 1 2 U18P16E0 book Page 13 Wednesday May 11 2011 3 49 PM...

Page 94: ...ll the panel off To install a panel 1 Place the panel in the original position 2 Install panel A Cowling YFZ45RSEB To remove the cowling 1 Remove panels A B and C 2 Loosen the quick fasteners and then take the cowling off U18P16E0 book Page 14 Wednesday May 11 2011 3 49 PM ...

Page 95: ...ica tion chart In addition the condition of the spark plug can reveal the condition of the engine The porcelain insulator around the center elec trode of the spark plug should be a medium to light tan the ideal color when the vehicle is ridden nor mally If the spark plug shows a distinctly different color the engine could be operating improperly Do not attempt to diagnose such problems your self I...

Page 96: ...possible EBU29499 Engine oil and oil filter element The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter element replaced at the intervals spec ified in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the ATV on a level surface 2 Start the engine warm it up until the engine oil has reached a normal tempe...

Page 97: ...t in and then remove it again to check the oil level TIP The engine oil should be between the minimum and maximum level marks 5 If the engine oil is at or below the minimum level mark add sufficient oil of the recom mended type through the engine oil tank filler hole to raise it to the correct level NOTICE Be sure the engine oil is at the correct lev el otherwise engine damage may result ECB00851 ...

Page 98: ... other wise oil may seep out when the engine is running ECB00362 To change the engine oil with or without oil fil ter element replacement 1 Place the ATV on a level surface 2 Remove the engine guard by removing the bolts 3 Start the engine warm it up for several min utes and then turn it off 4 Place an oil pan under the engine to collect the used oil 5 Remove the engine oil tank filler cap and the...

Page 99: ...TIP Skip steps 7 10 if the oil filter element is not being replaced 7 Remove the oil filter element cover by remov ing the bolts 1 Engine oil tank drain bolt 2 Gasket 1 2 1 Crankcase engine oil drain bolt 2 Gasket 1 2 U18P16E0 book Page 19 Wednesday May 11 2011 3 49 PM ...

Page 100: ...ngs are properly seated 10 Install the oil filter element cover by installing the bolts and then tighten them to the speci fied torque 1 Oil filter element cover 2 Bolt 1 2 1 Oil filter element 2 O ring Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kgf 7 2 ft lbf 1 2 2 U18P16E0 book Page 20 Wednesday May 11 2011 3 49 PM ...

Page 101: ...specification of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERV ING II or higher Make sure that no foreign material enters the crankcase 13 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause 14 Turn the engine off and then check the oi...

Page 102: ...aha dealer change the coolant WARNING Never attempt to remove the radiator cap when the engine is hot EWB02670 EBU27942 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 engine tempera ture 2 Check the coolant level in the coolant reser voir TIP The coolant should be between the minimum and maximum leve...

Page 103: ...e otherwise the effectiveness of the coolant will be reduced ECB01011 TIP The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If the engine overheats see page 8 54 for fur ther instructions EBU26806 Cleaning the air filter element The air filter element should be cleaned at the in tervals specified in the periodic maintenance and lubrication ch...

Page 104: ...air filter case cover by unhooking the holders 4 Fully loosen the wing bolt 5 Remove the air filter element together with the wing bolt and washer 1 Air filter case check hose 1 1 Air filter case cover 2 Air filter case cover holder 1 2 U18P16E0 book Page 24 Wednesday May 11 2011 3 49 PM ...

Page 105: ...an the 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 9 Squeeze the excess solvent out of the sponge material and let it dry NOTICE Do not twist the sponge material when squeezing it ECB00441 1 Air filter element 2 Washer 3 Wing bolt 3 2 1 1 Sponge material 2 Air filter element frame 1 2 U18P16E0...

Page 106: ...ull the sponge material over the air filter ele ment frame 13 Apply all purpose grease to the air filter ele ment seat 14 Install the washer onto the air filter element frame and then insert the wing bolt into the hole in the air filter element frame NOTICE Be sure to install the washer with its curved side facing outward as shown ECB00453 1 Air filter element seat 1 U18P16E0 book Page 26 Wednesda...

Page 107: ...ers onto the air filter case 17 Install the seat TIP The air filter element should be cleaned every 20 40 hours It should be cleaned and lubricated more often if the ATV is operated in extremely dusty ar eas Each time the air filter element maintenance is performed check the air inlet of the air filter case for obstructions Check the air filter case rubber joint to the throttle body and the rubber...

Page 108: ...he tailpipe and inside of the tailpipe housing 4 Insert the tailpipe into the muffler and align the bolt holes 5 Install the bolt and tighten it to the specified torque 6 Remove the purging bolt and the gasket 1 Tailpipe bolt 2 Tailpipe 1 2 1 Tailpipe 2 Spark arrester Tightening torque Tailpipe bolt 8 Nm 0 8 m kgf 5 8 ft lbf 1 2 U18P16E0 book Page 28 Wednesday May 11 2011 3 49 PM ...

Page 109: ...k arrester otherwise it could cause injury to the eyes burns carbon monox ide poisoning possibly leading to death and start a fire Always let the exhaust system cool prior to touching exhaust components Always wear eye protection and make sure no one is behind the ATV Make sure there are no combustible materi als in the area EBU29702 Adjusting the throttle lever free play The throttle lever free p...

Page 110: ...d 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 maintenance and lu brication chart EBU29601 Brakes Replacement of brake components requires pro fessional knowledge Brake service should be per formed by a Yamaha dealer WARNING EWB02571 Operating with improperly serviced or adjust ed brakes could lea...

Page 111: ...ke pads as a set TIP The wheels need to be removed to check the brake pads See page 8 50 EBU29831 Rear brake pads Each brake pad is provided with wear indicator grooves which allow you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the wear indica tor grooves If a brake pad has worn to the point that the wear indicator grooves have almost disa...

Page 112: ...servoir level Replenish the brake fluid if necessary Front brake Rear brake TIP To check the rear brake fluid level remove the seat See page 4 11 WARNING EWB02720 Improper maintenance can result in loss of braking ability Observe these precautions 1 Minimum level mark 1 1 Minimum level mark Specified brake fluid DOT 4 1 U18P16E0 book Page 32 Wednesday May 11 2011 3 49 PM ...

Page 113: ... may indicate worn brake pads and or brake system leakage therefore be sure to check the brake pads for wear and the brake system for leak age If the brake fluid level goes down suddenly have a Yamaha dealer check the cause before fur ther riding EBU24291 Changing the brake fluid Have a Yamaha dealer change the brake fluid at the intervals specified in the TIP after the periodic maintenance and lu...

Page 114: ...as shown If the brake pedal is not positioned as spec ified have a Yamaha dealer adjust it EBU24715 Adjusting the parking brake free play The parking brake free play must be checked and if necessary adjusted at the intervals specified in the periodic maintenance and lubrication chart Cable length A should measure 47 51 mm 1 85 2 01 in Adjust the parking brake free play as follows 1 No brake lever ...

Page 115: ...crease it TIP If the cable length cannot be adjusted to specifica tion consult a Yamaha dealer 6 Tighten the locknut on the brake cable 7 Slide the rubber cover to its original position 8 Turn in the adjusting bolt at the rear brake cal iper until it feels tight then turn it out 1 8 turn and tighten its locknut to the specified torque NOTICE When tightening the locknut 1 Adjusting bolt 2 Cable len...

Page 116: ...should come on just before braking takes effect The brake light switch for the brake pedal can be adjusted as follows but the front brake light switch should 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 direction a To make the brake light come on later tu...

Page 117: ...er cover back 4 Loosen the locknut 5 To increase the clutch lever free play turn the clutch lever free play adjusting nut located to wards the center of the cable in direction a and to decrease it turn the nut in direction b 6 Tighten the locknut 7 Slide the rubber cover to its original position TIP If the specified free play cannot be obtained as de scribed above or if the clutch does not operate...

Page 118: ... back and forth to locate the tightest portion of the drive chain and then measure the drive chain slack as shown 3 If the drive chain slack is incorrect adjust it as follows To adjust the drive chain slack 1 Place the ATV on a level surface 2 Loosen the rear wheel axle pinch bolts 3 Insert a rod of a diameter of 8 mm 0 3 in and a length of 10 cm 4 in into one of the holes in the drive chain tensi...

Page 119: ...as other vital parts of the ATV and can lead to drive chain slippage or breakage To pre vent this from occurring keep the drive chain slack within the specified limits ECB00542 6 Pull the rod out and then tighten the rear axle pinch bolts to the specified torque in the order shown 1 Rear wheel axle pinch bolt 2 Rod 3 Drive chain tensioner 4 Hole 3 4 2 1 1 Tightening torque Rear axle pinch bolt 21 ...

Page 120: ...h NOTICE To prevent dam aging the O rings do not clean the drive chain with steam cleaners high pressure washers or inappropriate solvents ECB00571 2 Wipe the drive chain dry 3 Thoroughly lubricate the drive chain with a special O ring chain lubricant NOTICE Do not use engine oil or any other lubricants for the drive chain as they may contain substances that could damage the O rings ECB00581 EBU24...

Page 121: ...thly before you begin riding in cold weather If the control cables are frozen or do not work smoothly you could be unable to control the ATV which could lead to an acci dent or collision EBU24922 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lubricated if necessary Brake lever Reco...

Page 122: ...ld be checked before each ride and the pedal pivot should be lubricated if necessary EBU24963 Checking the wheel hub bearings The front and rear wheel hub bearings must be checked at the intervals specified in the 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 Recommended lubricant L...

Page 123: ...BU25033 Lubricating the upper and lower arm pivots The upper and lower arm pivots must be lubricated at the intervals specified in the periodic mainte nance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun Recommended lubricant Lithium soap based grease Recommended lubricant Lithium soap based grease U18P16E0 book Page 43 Wednesday May 11 2011 3 49 PM ...

Page 124: ...e intervals specified in the periodic maintenance and lubrication chart TIP For parts equipped with a grease nipple use a grease gun 1 Upper grease nipple 2 Lower grease nipple 2 1 2 1 Upper grease nipple 2 Lower grease nipple Recommended lubricant Lithium soap based grease 1 2 2 U18P16E0 book Page 44 Wednesday May 11 2011 3 49 PM ...

Page 125: ...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 other sources of ig nition away Ventilate when charging or using in an enclosed space KEEP OUT OF REACH OF CHILDREN NOTICE ECB00620 Never attempt to remove the battery cell seals as this would permanent...

Page 126: ... 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 more than two months check it at least once a month and fully charge it if necessary NOTICE ECB00940 Always keep the battery charged Storing a dis charged battery can cause permanent battery damage To...

Page 127: ...installing the bolts 4 Install the seat See page 4 11 EBU29961 Replacing the fuse The fuse holder is located under the seat See page 4 11 If the fuse is blown replace it as follows 1 Turn the key to off and turn off all elec trical circuits NOTICE ECB00640 To prevent accidental short circuiting turn off the main switch when checking or replacing a fuse 1 Positive battery lead red 2 Negative batter...

Page 128: ...ey to on and turn on the elec trical circuits to check if the devices operate 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EBU30161 Replacing a headlight bulb If a headlight bulb burns out replace it as follows 1 Remove the headlight unit by removing the bolt and then pulling the headlight unit out ward as shown 2 Remove the headlight bulb holder cover Spe...

Page 129: ...ty of the bulb and the bulb life will be adversely affected Thoroughly clean off any dirt and fingerprints on the head light bulb using a cloth moistened with al cohol or thinner ECB00651 5 Install the headlight bulb holder by pushing it in and turning it clockwise 6 Install the headlight bulb holder cover 7 Place the headlight unit in the original posi tion and then install the bolt 1 Headlight b...

Page 130: ...ng bolt in direction a To lower a headlight beam turn the adjusting bolt in direction b EBU26920 Tail brake light This model is equipped with an LED type of tail brake light If the tail brake light does not come on have a Yamaha dealer check it EBU25651 Removing a wheel 1 Place the ATV on a level surface 2 Loosen the wheel nuts 1 Headlight beam adjusting bolt 1 a b U18P16E0 book Page 50 Wednesday ...

Page 131: ...all the wheel and the nuts TIP When installing the wheel make sure its arrow mark points toward the rotating direction of the wheel 3 Lower the ATV to the ground 4 Tighten the wheel nuts to the specified torques 1 Wheel nut 1 Arrow mark Tightening torques Front wheel nut 45 Nm 4 5 m kgf 33 ft lbf Rear wheel nut 45 Nm 4 5 m kgf 33 ft lbf U18P16E0 book Page 51 Wednesday May 11 2011 3 49 PM ...

Page 132: ...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 may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills WARNING EWB02280 Do not smoke when checking the fuel system Fuel can ignite or...

Page 133: ...he 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 Have a Yamaha dealer check the ATV The engine does not start Check the battery Dry Wet Operate the electric starter The engine does not start Have a Yamaha dealer check the ATV Operate the electric starter 4 Battery The engine turns over quickly The en...

Page 134: ... 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 coolant level is OK The coolant level is low Check the cooling system for leakage Have a Yamaha dealer check and repair the cooling system Add coolant See TIP Start the engine If the engine overheats ...

Page 135: ...s 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 bills have resulted from improper high pressure detergent applica tions such as those available in coin oper ated car washers ECB00711 4 Once most of the dirt has been hosed off wash all surfaces with warm water and mild det...

Page 136: ...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 onto the spark plug and then place the spark plug on the cylinder head so that the electrodes are grounded This will limit sparking during the next step d Turn the engine over several times with the starter This will coat the cylinder wall with oil e Remove the spark plug cap ...

Page 137: ... 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 more than 30 C 90 F For more in formation on storing the battery see page 8 45 TIP Make any necessary repairs before storing the ATV U18P16E0 book Page 3 Wednesday May 11 2011 3 49 PM ...

Page 138: ...e DOHC Cylinder arrangement Forward inclined single cylinder Displacement 449 cm Bore stroke 95 0 63 4 mm 3 74 2 50 in Compression ratio 11 40 1 Starting system Electric starter Lubrication system Dry sump Engine oil Recommended brand YAMALUBE Type SAE 5W 30 10W 30 10W 40 15W 40 20W 40 or 20W 50 Recommended engine oil grade API service SG type or higher JASO standard MA 0 10 30 50 70 90 110 130 F ...

Page 139: ... Imp gal Fuel reserve amount 3 4 L 0 90 US gal 0 75 Imp gal Fuel injection Throttle body ID mark 18P1 00 Spark plug s Manufacturer model NGK CR8E Spark plug gap 0 7 0 8 mm 0 028 0 031 in Clutch Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 61 23 2 652 Secondary reduction system Chain drive Secondary reduction ratio 38 14 2 714 Transmission ty...

Page 140: ... 0 psi Rear 30 0 kPa 0 300 kgf cm 4 4 psi Minimum Front 24 5 kPa 0 245 kgf cm 3 6 psi Rear 27 0 kPa 0 270 kgf cm 4 0 psi Front wheel Wheel type Panel wheel Rim size 10 x 5 5AT Rear wheel Wheel type Panel wheel Rim size 9 x 8 0AT Front brake Type Disc brake Operation Right hand operation Specified brake fluid DOT 4 Rear brake Type Disc brake Operation Right foot operation Specified brake fluid DOT ...

Page 141: ...ging system AC magneto Battery Model YTZ7S Voltage capacity 12 V 6 0 Ah Headlight Bulb type Krypton bulb Bulb voltage wattage quantity Headlight 12 V 30 0 30 0 W 2 Tail brake light LED Neutral indicator light LED Fuel level warning light LED Coolant temperature warning light LED Engine trouble warning light LED Fuse Fuse 20 0 A U18P16E0 book Page 4 Wednesday May 11 2011 3 49 PM ...

Page 142: ... erence in case the ATV is stolen KEY IDENTIFICATION NUMBER VEHICLE IDENTIFICATION NUMBER MODEL LABEL INFORMATION EBU26020 Key identification number The key identification number is stamped into the key Record this number in the space provided and use it for reference when ordering a new key EBU26030 Vehicle identification number The vehicle identification number is stamped into the frame 1 Key id...

Page 143: ...on will be need ed when ordering spare parts from a Yamaha deal er EBU29662 Vehicle Emission Control Information label The Vehicle Emission Control Information label is affixed at the location in the illustration This label shows specifications related to exhaust emissions as required by federal law state law and Environ ment Canada 1 Vehicle identification number 1 1 Model label 1 U18P16E0 book P...

Page 144: ...11 3 11 1 Vehicle Emission Control Information label 1 U18P16E0 book Page 3 Wednesday May 11 2011 3 49 PM ...

Page 145: ...pose of noise control prior to its sale or delivery to the ul timate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Exhaust system M...

Page 146: ... the maintenance work is required It is not acceptable proof of maintenance work MAINTENANCE INTERVAL DATE OF SERVICE MILEAGE SERVICING DEALER NAME AND ADDRESS REMARKS month km mi hours 1 320 200 20 3 1300 800 80 6 2500 1600 160 12 5000 3200 320 18 7500 4800 480 24 10000 6400 640 30 12500 8000 800 36 15000 9600 960 42 17500 11200 1120 48 20000 12800 1280 54 22500 14400 1440 60 25000 16000 1600 U18...

Page 147: ...bsequent pur chaser s it is imperative that the machine be inspected and registered for warranty by an autho rized Yamaha ATV dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSION CONTROL SYSTEM WARRANTY Yamaha Motor Corporation USA also wa...

Page 148: ...d upon your request at any later date 3 Each Yamaha ATV dealer is held responsible for his setup service and war ranty repair work Q Is the warranty transferable to second owners A Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha ATV dealer for the policy to remain effective CUSTOMER SERVICE If your ma...

Page 149: ... to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 250 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodgi...

Page 150: ... within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 Indicates a hazardous situation which if not avoided could result in death or serious injury WA...

Page 151: ...lay adjusting 8 36 Coolant 5 4 8 22 Coolant temperature warning light 4 2 Cowling and panels removing and installing 8 9 D Drive chain 5 5 Drive chain lubricating 8 40 Drive chain slack 8 38 E Engine break in 6 4 Engine oil 5 4 Engine oil and oil filter element 8 16 Engine start 6 1 Engine stop switch 4 3 Engine trouble warning light 4 3 F Fuel 4 9 5 4 Fuel level warning light 4 3 Fuel tank cap 4 ...

Page 152: ...ock absorber assembly adjusting the rear 4 16 Spark arrester cleaning 8 27 Spark plug checking 8 15 Specifications 10 1 Speed limiter 4 5 Start switch 4 4 Steering shaft lubricating 8 44 Storage 9 2 Suspension lubricating the upper and lower arm pivots 8 43 Swingarm pivots lubricating 8 43 T Tail brake light 8 50 Throttle lever 4 4 5 5 Throttle lever free play adjusting 8 29 Tires 5 5 Troubleshoot...

Page 153: ...Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory manual for your vehicle that the technici...

Page 154: ...pavement may seriously affect handling and control Improper ATV use can result in SEVERE INJURY or DEATH NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROT...

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Yamaha YFZ450R, Owner'S Manual

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