warning YAMAHA YFZ450 2009 Workshop Manual

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parking brake lever to the right.
2. Fully loosen the locknut and the adjusting bolt
at the rear brake caliper.
3. Loosen the locknut on the brake cable.
4. Turn the adjusting nut on the brake cable in di-
rection (a) to increase the cable length, and in
direction (b) to decrease it.
TIP

If the cable length cannot be adjusted to specifica-
tion, consult a Yamaha dealer.
5. Tighten the locknut on the brake cable.6. 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

ECB00520
When tightening the locknut, hold the adjust-
ing bolt with a wrench so that it does not turn
together with the locknut.
WARNING

EWB02090
Operating with improperly serviced or adjust-
ed brakes could cause the brakes to malfunc-
tion, resulting in reduced braking
performance. This could increase the chance
of a collision or accident. After adjusting the
parking brake free play, block the rear of the
ATV off the ground and spin the rear wheels.
Check to make sure there is no brake drag. If
brake drag is noticed, perform the adjustment
again.
1. Locknut
2. Adjusting nut
(a)
(b)
12

Tightening torque:
Locknut (rear brake caliper):
16 Nm (1.6 m·kgf, 12 ft·lbf)

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WARNING

EWB02130
Inspect cables frequently and replace if dam-
aged. Corrosion can result when the cable
sheaths become damaged, and cables can
also become frayed or kinked, which could re-
strict the operation of controls and lead to an
accident or injury.
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
Clutch lever
Recommended lubricants:
Brake lever:
Silicone grease
Clutch lever:
Lithium-soap-based grease

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Right side

EBU25224
Battery
This model is equipped with a VRLA (Valve Regu-
lated Lead Acid) battery. There is no need to check
the electrolyte or to add distilled water. However,
the battery lead connections need to be checked
and, if necessary, tightened.
NOTICE

ECB00620
Never attempt to remove the battery cell seals,
as this would permanently damage the battery.WARNING

EWB02160
Battery electrolyte is poisonous and danger-
ous, as it contains sulfuric acid, which can
cause severe burns. Avoid contact with skin,
eyes or clothing. Always shield your eyes
when working near batteries.
Antidote:
EXTERNAL: Flush with water.
INTERNAL: Drink large quantities of water or
milk. Follow with milk of magnesia, 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.
To remove the battery
1. Remove the seat. (See page 4-11.)
2. Unhook the band securing the owner’s tool kit,
and then remove the battery holding plate by
removing the bolts.
3. Disconnect the negative battery lead first,
1. Upper grease nipple
2. Lower grease nipple
2 1

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NOTICE

ECB00640
To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse.
2. Remove the blown fuse, and then install a
new fuse of the specified amperage.
WARNING

EWB02171
Always use a fuse of the specified rating, and
never use a substitute object in place of the
proper fuse. An improper fuse or a substitute
object can cause damage to the electrical sys-
tem, which could lead to a fire.
3. Turn the key to “ON” and turn on the electrical
circuits to check if the devices operate.
4. If the fuse immediately blows again, have a
Yamaha dealer check the electrical system.
EBU25440
Replacing a headlight bulb
If a headlight bulb burns out, replace it as follows.
1. Remove the headlight unit by removing the
bolts.
2. Disconnect the headlight coupler.
3. Remove the headlight bulb holder cover. Specified fuse:
15.0 A
1. Headlight assembly
2. Bolt
21

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4. Remove the headlight bulb holder by pushing
it in and turning it counterclockwise, and then
remove the defective bulb.WARNING
EWB02230
Do not touch a headlight bulb when it is on or
immediately after it is turned off. You can be
burned or a fire could start if the bulb touches
something flammable. Wait for the bulb to cool
before touching or removing it.
5. Place a new headlight bulb into position.
1. Headlight bulb holder cover
2. Headlight coupler
1
2

1. Headlight bulb holder
1

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wheel.
Front
3. Lower the ATV to the ground.
4. Tighten the wheel nuts to the specified
torques.
EBU25740
Troubleshooting
Although Yamaha ATVs receive a thorough in-
spection before shipment from the factory, trouble
may occur during operation. Any problem in the fu-
el, compression, or ignition systems, for example,
can cause poor starting and loss of power.
The following troubleshooting charts represent
quick and easy procedures for checking these vital
systems yourself. However, should your ATV re-
quire any 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 explode, causing severe inju-
ry or property damage. Make sure there are no
open flames or sparks in the area, including pi-
lot lights from water heaters or furnaces.
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)

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Engine overheating
WARNING

EWB02290
Wait for the engine and radiator to cool before removing the radiator cap. You could be burned by
hot fluid and steam blown out under pressure. Always put a thick rag over the cap when opening.
Allow any remaining pressure to escape before completely removing the cap.
TIP

If coolant is not available, tap water 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 again, have a
Yamaha dealer check and repair the cooling system.
There is
leakage.
There is
no leakage.

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EBU25860
CLEANING AND STORAGE
EBU25900
Cleaning
Frequent, thorough cleaning of your ATV will not
only enhance its appearance but will improve its
general performance and extend the useful life of
many components.
1. Before cleaning the ATV:
a. Block off the end of the exhaust pipe to
prevent water entry. A plastic bag and
strong rubber band may be used.
b. Make sure the spark plug and all filler caps
are properly installed.
2. If the engine case is excessively greasy, apply
degreaser with a paint brush. Do not apply de-
greaser to the chain, sprockets or wheel ax-
les.
3. Rinse the dirt and degreaser off with a garden
hose. Use only enough pressure to do the job.
NOTICE

ECB00710
Excessive water pressure may cause water
seepage and deterioration of wheel bearings,
brakes, transmission seals and electrical de-
vices. Many expensive repair bills have result-ed from improper high-pressure detergent
applications such as those available in coin-
operated car washers.
4. Once most of the dirt has been hosed off,
wash all surfaces with warm water and mild,
detergent-type soap. An old toothbrush or bot-
tle brush is handy for hard-to-reach places.
5. Rinse the ATV off immediately with clean wa-
ter and dry all surfaces with a chamois, clean
towel or soft absorbing cloth.
6. Dry the chain and lubricate it to prevent it from
rusting.
7. Clean the seat with a vinyl upholstery cleaner
to keep the cover pliable and glossy.
8. Automotive type wax may be applied to all
painted and chrome plated surfaces. Avoid
combination cleaner-waxes. Many contain
abrasives which may mar the paint or protec-
tive finish. When finished cleaning, start the
engine and let it idle for several minutes.
WARNING

EWB02310
Wet brakes may have reduced stopping ability,

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Operation:
Right foot operation
Recommended fluid:
DOT 4
Front suspension:
Type:
Double wishbone
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
230 mm (9.1 in)
Rear suspension:
Type:
Swingarm (link suspension)
Spring/shock absorber type:
Coil spring/gas-oil damper
Wheel travel:
270 mm (10.6 in)
Electrical system:
Ignition system:
DC. CDI
Charging system:
AC magneto
Battery:
Model:
GT7B-4
Voltage, capacity:
12 V, 6.5 Ah
Headlight:
Bulb type:
Krypton bulb
Bulb voltage, wattage
×
quantity:
Headlight:
12 V, 30.0/30.0 W
×
2
Tail/brake light:
12 V, 0.5/3.9 W
×
1
Neutral indicator light:
12 V, 1.7 W
×
1
Coolant temperature warning light:
12 V, 1.7 W
×
1

Fuses:
Main fuse:
15.0 A

INDEX
A
Accessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-24
B
Battery .......................................................................... 8-47
Brake and clutch levers, checking and lubricating ....... 8-44
Brake and shift pedals, checking and lubricating ......... 8-45
Brake fluid, changing.................................................... 8-35
Brake fluid level, checking............................................ 8-32
Brake lever ..................................................................... 4-5
Brake lever free play, checking the front ...................... 8-36
Brake light switches ..................................................... 8-39
Brake pads, checking the front and rear ...................... 8-31
Brake pedal .................................................................... 4-6
Brake pedal position, checking .................................... 8-36
Brakes, front and rear .................................................... 5-3
C
Cables, checking and lubricating ................................. 8-43
Carburetor, adjusting.................................................... 8-29
Chassis fasteners........................................................... 5-7
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-5
Clutch lever free play, adjusting ................................... 8-39
Coolant ................................................................. 5-3
,
8-20
Coolant temperature warning light ................................. 4-1
D
Drive chain ..................................................................... 5-4
Drive chain, lubricating ................................................. 8-43
Drive chain slack .......................................................... 8-41
E
Engine break-in .............................................................. 6-5
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-30
Engine oil ....................................................................... 5-3
Engine oil and oil filter element .................................... 8-14
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-2
F
Fuel ........................................................................ 4-8
,
5-3
Fuel cock ........................................................................ 4-9
Fuel tank cap.................................................................. 4-7
Fuse, replacing............................................................. 8-49
H
Handlebar switches ........................................................ 4-2
Headlight beam, adjusting............................................ 8-52
Headlight bulb, replacing.............................................. 8-50
I
Identification numbers .................................................. 11-1
Indicator light and warning light...................................... 4-1
Instruments, lights and switches .................................... 5-7