YAMAHA YFZ450R 2012 Owners Manual

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8
EBU21865General maintenance and lubrication chart TIP
For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.
Items marked with an asterisk should 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 month136612
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 for fluid leakage, and
correct if necessary. √√√√√
 Replace brake pads. Whenever worn to the limit
4 *Rear brake 
Check 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
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5*Brake hoses 
Check for cracks or other damage, and replace if
necessary. √√√√
 Replace. Every 4 years
6 *Parking brake Check operation and adjust if necessary. √√√√√
7 *Wheels 
Check runout and for damage, and replace if nec-
essary. √ √√√
8 *Tires 
Check tread depth and for damage, and replace if
necessary.
 Check air pressure and balance, and correct if
necessary. √ √√√
9 *Wheel hub bearings 
Check for looseness or damage, and replace if
necessary. √ √√√
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. √√√
NO. ITEM
CHECK OR MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U18P66E0.book Page 6 Monday, May 16, 2011 4:23 PM

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14*Chassis fasteners 
Make sure that all nuts, bolts, and screws are
properly tightened. √√√√√
15 *Shock absorber as-
semblies 
Check operation and correct if necessary.
 Check for oil leakage and replace if necessary. √√√
16 *Rear suspension re-
lay arm and con-
necting arm
pivoting 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 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 INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U18P66E0.book Page 7 Monday, May 16, 2011 4:23 PM

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EBU29430TIP
Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or
muddy areas, or at full-throttle.
Replace the fuel hose every five years and if cracked or damaged.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
 Every two years replace the internal components of the brake master cylinders and calipers, 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 MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U18P66E0.book Page 8 Monday, May 16, 2011 4:23 PM

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EBU30130Removing and installing the cowling
and panels The cowling and panels shown need to be re-
moved to perform some of the maintenance jobs
described in this chapter. Refer to this section each
time a cowling or panel needs to be removed and
installed.
EBU29538Panel A (YFZ450RB)
To remove the panel1. Remove the seat. (See page 4-10.)
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. Panel C
1
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8-10
84. Remove the quick fasteners, and then slide
the panel backward and pull upward. 5. Install the fuel tank cap by turning it clockwise.
To install the panel
1. Remove the fuel tank cap by 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
11
2
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Panels B and C (YFZ450RB)
To remove a panel
1. Remove panel A.
2. Pull the panel off.
To install a panel1. Place the panel in the original position. 2. Install panel A.
Cowling (YFZ450RB)
To remove the cowling
1. Remove panels A, B and C.
2. Remove the bolts, and then take the cowling off.
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8To install the cowling
1. Place the cowling in the original position, and
then install the bolts.
2. Install panels C, B and A.EBU29595Panel A (YFZ450RSEB)
To remove the panel1. Remove the seat. (See page 4-10.)
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
11
1
1
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4. Remove the quick fasteners, and then slide
the panel backward and pull upward. 5. Install the fuel tank cap by turning it clockwise.
To install the panel
1. Remove the fuel tank cap by 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. 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
11
2
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8Panels B and C (YFZ450RSEB)
To remove a panel
1. Remove panel A.
2. Pull the panel off.
To install a panel1. Place the panel in the original position. 2. Install panel A.
Cowling (YFZ450RSEB)
To remove the cowling
1. Remove panels A, B and C.
2. Loosen the quick fasteners, and then take the cowling off.
U18P66E0.book Page 14 Monday, May 16, 2011 4:23 PM