air filter YAMAHA WOLVERINE 450 2009 Owners Manual

OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Engine break-in .......................................... 6-5
Parking ....................................................... 6-5
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
JUDGEMENT ............................................ 7-2
BE CAREFUL WHERE YOU RIDE ............. 7-9
TURNING YOUR ATV .............................. 7-12
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW
WATER ................................................... 7-19
RIDING OVER ROUGH TERRAIN ........... 7-22
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23PERIODIC MAINTENANCE AND MINOR
REPAIR ..........................................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance chart for the
emission control system ...........................8-3
General maintenance and lubrication
chart ..........................................................8-5
Removing and installing cowlings and
panels .......................................................8-9
Checking the spark plug ...........................8-15
Engine oil and oil filter cartridge ................8-17
Final gear oil .............................................8-22
Changing the differential gear oil ..............8-25
Coolant .....................................................8-27
Cleaning the air filter element ...................8-31
Cleaning the spark arrester ......................8-34
V-belt cooling duct check hose .................8-35
V-belt case drain plug ...............................8-36
Adjusting the carburetor ............................8-36
Adjusting the engine idling speed .............8-36
Adjusting the throttle cable free play .........8-38
Valve clearance ........................................8-38
Adjusting the drive select lever safety
system cable ...........................................8-39
Checking the front and rear brake pads ...8-39
Checking the brake fluid level ...................8-40
Changing the brake fluid ...........................8-41U3C263E0.book Page 2 Thursday, May 15, 2008 10:44 AM

3-1
3
EBU17680
DESCRIPTION
EBU17690Left view
EBU17700Right view
1. Front shock absorber assembly spring preload adjusting
ring
2. Fuel cock
3. Air filter case
4. Fuses
5. Storage compartment and tool kit
6. Seat lock lever
7. Rear shock absorber assembly spring preload adjusting
ring
8. Engine oil filler cap
9. Oil filter cartridge
10.Coolant reservoir
11.V-belt cooling duct check hose
1. Spark arrester
2. Tail/brake light
3. Battery
4. Spark plug
5. Rear brake fluid reservoir
6. Radiator cap
7. Front shock absorber assembly spring preload adjusting
ring
8. Rear brake light switch
9. Brake pedal
10.V-belt case drain plug
U3C263E0.book Page 1 Thursday, May 15, 2008 10:44 AM

7-20
7 Test your brakes after leaving the water. Do not
continue to ride your ATV without verifying that you
have regained proper braking ability.
NOTICEECB00730After riding your ATV in water, be sure to drain
the trapped water by removing the check hose
at the bottom of the air filter case, the V-belt
cooling duct check hose, the drive select lever
box check hose and the storage compartment
drain plugs. Also, remove the V-belt case drainplug to drain any water that may have accumu-
lated. Wash the ATV in fresh water if it has been
operated in salt water or muddy conditions.1. Air filter case check hose
U3C263E0.book Page 20 Thursday, May 15, 2008 10:44 AM

8-5
8
EBU21864General maintenance and lubrication chart NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
1 Air filter elementClean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
2*Front brakeCheck operation and correct if necessary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
3*Rear brakeCheck operation and correct if necessary.
Check brake lever free play and adjust if neces-
sary.
Check fluid level and ATV for fluid leakage, and
correct if necessary.√√√√√
Replace brake pads. Whenever worn to the limit
4*Brake hosesCheck for cracks or other damage, and replace if
necessary.√√√√
Replace. Every 4 years
5*WheelsCheck runout and for damage, and replace if nec-
essary.√ √√√
6*TiresCheck tread depth and for damage, and replace if
necessary.
Check air pressure and balance, and correct if
necessary.√ √√√
7*Wheel hub bearingsCheck for looseness or damage, and replace if
necessary.√ √√√
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8-6
8
8*SwingarmCheck for excessive play, and correct if necessary.√√√
9*V- b e l tCheck for wear, cracks or other damage, and re-
place if necessary.√ √√√
10*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√
11*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
12*Steering shaftLubricate with lithium-soap-based grease.√√√
13*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
14*Engine mountCheck for cracks or other damage, and replace if
necessary.√√√
15*Axle bootsCheck for cracks or other damage, and replace if
necessary.√√√√√
16 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
17Engine oil filter car-
tridgeReplace.√√√
18*Engine oil strainerClean.√√√
19 Differential gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320
U3C263E0.book Page 6 Thursday, May 15, 2008 10:44 AM

8-7
8
EBU23070TIP
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.20 Final gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√
21 Cooling systemCheck coolant level and ATV for coolant leakage,
and correct if necessary.√√√√√
Replace coolant. Every 2 years
22*Moving parts and
cablesLubricate.√√√√
23*Drive select lever
safety system cableCheck operation and adjust or replace if neces-
sary.√√√
24*Throttle lever hous-
ing and cableCheck operation and correct if necessary.
Check throttle cable free play and adjust if neces-
sary.
Lubricate throttle lever housing and cable.√√√√√
25*Front and rear brake
switchesCheck operation and correct if necessary.√√√√√
26*Lights and switchesCheck operation and correct if necessary.
Adjust headlight beams.√√√√√ NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320U3C263E0.book Page 7 Thursday, May 15, 2008 10:44 AM

8-31
8

If water has been used instead of coolant, re-
place it with coolant as soon as possible,
otherwise the cooling system will not be pro-
tected against frost and corrosion.
If water has been added to the coolant, have
a Yamaha dealer check the antifreeze con-
tent of the coolant as soon as possible, oth-
erwise the effectiveness of the coolant willbe reduced.
13. Install the radiator cap, start the engine, let it
idle for several minutes, and then turn it off.
14. Remove the radiator cap to check the coolant
level in the radiator. If it is low, add sufficient
coolant until it reaches the top of the radiator,
and then install the radiator cap.
15. Start the engine, and then check for coolant
leakage.TIPIf any leakage is found, have a Yamaha dealercheck the cooling system.
16. Install the cowling.
17. Install the panels.
EBU23645Cleaning the air filter element The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean or, if necessary, replace
the air filter element more frequently if you are
riding in unusually wet or dusty areas.TIPThere is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-ter case.
1. Place the ATV on a level surface.1. Air filter case check hose
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8-32
8 2. Remove the seat. (See page 4-12.)
3. Remove the air filter case cover by unhooking
the air filter case cover holders.
4. Pull the air filter element out of the air filter
case.5. Pull off the air filter element lock plate, and
then remove the sponge material from the air
filter element frame.
1. Air filter case cover holder
2. Air filter case cover
1. Air filter element
U3C263E0.book Page 32 Thursday, May 15, 2008 10:44 AM

8-33
86. Wash the sponge material gently but thor-
oughly in solvent.
WARNING
EWB01940Always use parts cleaning solvent to clean the
sponge material. Never use low-flash-point
solvents or gasoline to clean the sponge mate-
rial because the engine could catch fire or ex-plode.
7. Squeeze the excess solvent out of the sponge
material and let it dry.
NOTICEECB00440Do not twist the sponge material when squeez-ing it.
8. Check the sponge material and replace it if
damaged.
9. Apply a quality foam air filter oil to the sponge
material.TIPThe sponge material should be wet but not drip-ping.
10. Pull the sponge material over the air filter ele-
ment frame, and then install the lock plate.
1. Air filter element frame
2. Sponge material
3. Air filter element lock plateU3C263E0.book Page 33 Thursday, May 15, 2008 10:44 AM

8-34
8 11. Insert the air filter element into the air filter
case, and then install the air filter case cover
by hooking the holders onto the air filter case.
12. Install the seat.
TIPThe 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 carburetor fittings and the rubber joint
manifold fittings for an air-tight seal. Tighten all fit-
tings securely to avoid the possibility of unfilteredair entering the engine.NOTICEECB00460
Make sure that the air filter element is prop-
erly seated in the air filter case.
Never operate the engine with the air filter el-
ement removed. This will allow unfiltered air
to enter the engine, causing rapid engine
wear and possible engine damage. Addition-
ally, operation without the air filter elementwill affect carburetor jetting with subsequent
poor performance and possible engine over-
heating.EBU27011Cleaning the spark arrester Be sure the exhaust pipe and muffler are cool be-
fore cleaning the spark arrester.
1. Remove the tailpipe cover by removing the
bolts.
2. Remove the tailpipe by pulling it out of the
muffler.1. Bolt
2. Tailpipe cover
U3C263E0.book Page 34 Thursday, May 15, 2008 10:44 AM