check engine YAMAHA YFZ450R 2009 User Guide

8-5
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78
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11

10
*
Swingarm pivots

Check operation and for excessive play, and
replace 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 rollers


Check for wear and replace if necessary.
√√√
14
*
Chassis fasteners


Make sure that all nuts, bolts, and screws are
properly tightened.
√√√√√
15
*
Shock absorber
assemblies


Check operation and correct if necessary.

Check for oil leakage and replace if necessary.
√√√
16
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points


Check operation and correct if necessary.
√√√√
17
*
Steering shaft


Lubricate with lithium-soap-based grease.
√√√
18
*
Steering system


Check operation and repair or replace if damaged.

Check toe-in and adjust if necessary.
√√√√√
19
*
Engine mount


Check for cracks or other damage, and replace if
necessary.
√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1300
(800)2500
(1600)2500
(1600)5000
(3200)
hours 20 80 160 160 320

8-6
1
2
3
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5
6
78
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11

20 Engine oil

Change.

Check ATV for oil leakage, and correct if neces-
sary.
√ √√√
21Engine oil filter ele-
ment

Replace.
√√√
22 Cooling system

Check coolant level and ATV for coolant leakage,
and correct if necessary.
√√√√√

Replace coolant. Every 2 years
23
*
Moving parts and
cables

Lubricate.
√√√√
24
*
Throttle lever hous-
ing and cable


Check 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
switches

Check operation and correct if necessary.
√√√√√
26
*
Lights and switches

Check 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 80 160 160 320

8-13
1
2
3
4
5
6
78
9
10
11

EBU29440
Checking the spark plug
The spark plug is an important engine component,
which should be checked periodically, preferably
by a Yamaha dealer. Since heat and deposits will
cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
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. Instead, have a Yamaha dealer check the ve-
hicle.
If a spark plug shows signs of electrode erosion
and excessive carbon or other deposits, it should
be replaced.
Before installing a spark plug, the spark plug gap
should be measured with a wire thickness gaugeand, if necessary, adjusted to specification.
Clean the surface of the spark plug gasket and its
mating surface, and then wipe off any grime from
the spark plug threads.
Specified spark plug:
NGK/CR8E
1. Spark plug gap
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
Tightening torque:
Spark plug:
12.5 Nm (1.3 m·kgf, 9.4 ft·lbf)

8-14
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78
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11
TIP

If a torque wrench is not available when installing
a spark plug, a good estimate of the correct torque
is 1/4–1/2 turn past finger tight. However, the spark
plug should be tightened to the specified torque as
soon as possible.
EBU29492
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 temperature of 40 °C
(104 °F), let it continue to idle for ten seconds
or more, and then turn the engine off.
TIP

To achieve the proper engine oil temperature for
an accurate oil level reading, the engine must have
first completely cooled down, and then warmed up
again for several minutes to normal operating tem-
perature.
3. Remove the engine oil tank filler cap, and
wipe the dipstick off with a clean rag.
4. Insert the dipstick into the filler hole (without
screwing it in), and then remove it again to
check the oil level.TIP

The engine oil should be between the minimum
1. Engine oil tank filler cap
2. Dipstick
3. Maximum level mark
4. Minimum level mark
11
2
3
4

8-16
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2
3
4
5
6
78
9
10
11

6. Remove the engine oil tank filler cap and the
engine oil tank drain bolt.7. Check the washers for damage, and replace if
necessary.
TIP

Skip steps 8–11 if the oil filter element is not being
replaced.
8. Remove the oil filter element cover by remov-
ing the bolts, and then remove the oil filter el-
ement.
1. Crankcase engine oil drain bolt
1

1. Engine oil tank drain bolt
1

8-19
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78
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minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
15. Turn the engine off, and then check the oil lev-
el and correct it if necessary.
16. Install the engine guard by installing the bolts,
and then tighten them to the specified torque.
NOTICE

ECB00370
Be sure to apply LOCTITE® to the engine
guard bolts before installing them.
EBU23470
Coolant
The coolant level should be checked before each
ride. In addition, the coolant must be changed at
the intervals specified in the periodic maintenance
and lubrication chart.
EBU23482
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 level marks.
3. If the coolant is at or below the minimum level
mark, remove the reservoir cap, add coolant
or distilled water to the maximum level mark,
and then install the reservoir cap. Tightening torque:
Engine guard bolt:
7 Nm (0.7 m·kgf, 5 ft·lbf)

8-20
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78
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11
NOTICE

ECB00401

If coolant is not available, use distilled water
or soft tap water instead. Do not use hard wa-
ter or salt water since it is harmful to the en-
gine.

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 will
be reduced.TIP
If the engine overheats, see page 8-52 for further
instructions.
EBU23561
To change the coolantWARNING
EWB01890
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 place a thick rag over the cap
when opening. Allow any remaining pressure
to escape before completely removing the cap.
1. Place the ATV on a level surface.
2. Remove panel F. (See page 8-8.)
3. Place a container under the engine, and then
1. Coolant reservoir cap
2. Maximum level mark
3. Minimum level mark
Coolant reservoir capacity (up to the maximum
level mark):
0.25 L (0.26 US qt, 0.22 Imp.qt)
1
2
3

8-23
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78
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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 will
be reduced.
12. Install the radiator cap, start the engine, let it
idle for several minutes, and then turn it off.
13. 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.
14. Start the engine, and then check for coolant
leakage.
TIP

If any leakage is found, have a Yamaha dealer
check the cooling system.
15. Install the panel.
EBU26802
Cleaning the air filter element
The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean the air filter element morefrequently if you are riding in unusually wet or dusty
areas.
TIP

There 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.
2. Remove the seat. (See page 4-10.)
3. Remove the air filter case cover by unhooking
the holders.
1. Air filter case check hose
1

8-25
1
2
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78
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11

8. Wash the sponge material gently but thor-
oughly in solvent.
WARNING

EWB01940
Always 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.
9. Squeeze the excess solvent out of the sponge
material and let it dry.
NOTICE
ECB00440
Do not twist the sponge material when squeez-
ing it.
10. Check the sponge material and replace it if
damaged.
11. Apply a quality foam air filter oil to the sponge
material.TIP

The sponge material should be wet but not drip-
ping.
12. Pull the sponge material over the air filter ele-
ment frame.
1. Sponge material
2. Air filter element frame
1 2

8-26
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78
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13. 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

ECB00451
Be sure to install the washer with the bent edge
facing outward as shown.
14. Insert the air filter element into the air filter
case, and then tighten the wing bolt.
15. Install the air filter case cover by hooking the
holders onto the air filter case.
16. 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 joint mani-
fold fittings for an air-tight seal. Tighten all fittings
securely to avoid the possibility of unfiltered air en-
tering the engine.NOTICE
ECB00760

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 element
will affect the fuel injection system with sub-
sequent poor performance and possible en-
gine overheating.
1. Washer
1