maintenance YAMAHA WOLVERINE 450 2008 User Guide

8-7
8
EBU23070NOTE:
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 320U3C262E0.book Page 7 Tuesday, June 26, 2007 3:36 PM

8-9
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EBU26401Removing and installing cowlings and
panels The cowlings 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.
EBU26582Cowling A
To remove the cowling1. Remove cowling B.
2. Remove panel B.
3. Disconnect the speedometer unit couplers.
1. Panel A
1. Panel B
2. Cowling A
3. Cowling B
4. Panel C
5. Panel D
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8-15
8To install the panel
Place the panel in its original position.
EBU23211Checking the spark plug The spark plug is an important engine component,
which is easy to check. 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.
To remove the spark plug
1. Remove the spark plug cap.
1. Panel D
1. Spark plug cap
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82. Clean the surface of the spark plug gasket
and its mating surface, and then wipe off any
grime from the spark plug threads.
3. Install the spark plug with the spark plug
wrench, and then tighten it to the specified
torque.
NOTE: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 assoon as possible.
4. Install the spark plug cap.EBU26425Engine oil and oil filter cartridge The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter cartridge 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. Remove panel D. (See page 8-9.)
3. Check the engine oil level on a cold engine.NOTE:If the engine was started before checking the oil
level, be sure to warm up the engine sufficiently,
and then wait at least ten minutes until the oil set-tles for an accurate reading.
1. Spark plug gapTightening torque:
Spark plug:
17.5 Nm (1.75 m·kgf, 12.7 ft·lbf)
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8

Make sure that no foreign material enters thecrankcase.
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, wait at least ten minutes,
and then check the oil level and correct it if
necessary.
15. Install panel D.EBU23381Final gear oil The final gear case must be checked for oil leak-
age before each ride. If any leakage is found, have
a Yamaha dealer check and repair the ATV. In ad-
dition, the final gear oil level must be checked and
the oil changed as follows at the intervals specified
in the periodic maintenance and lubrication chart.
To check the final gear oil level
1. Place the ATV on a level surface.NOTE:The final gear oil level must be checked on a coldengine.2. Remove the final gear oil filler bolt, and then
check the oil level in the final gear case.
NOTE:The oil level should be at the brim of the filler hole.
3. If the oil is below the brim of the filler hole, add
sufficient oil of the recommended type to raise
it to the correct level.
4. Install the oil filler bolt, and then tighten it to the
specified torque.1. Final gear oil
2. Final gear oil filler bolt
3. Correct oil level
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CAUTION:ECB00420Be sure no foreign material enters the finalgear case.
7. Install the oil filler bolt, and then tighten it to the
specified torque.8. Check the final gear case for oil leakage. If oil
is leaking, check for the cause.
9. Install the final gear case guard by installing
the bolts and tightening them to the specified
torque.
EBU23431Changing the differential gear oil The differential gear case must be checked for oil
leakage before each ride. If any leakage is found,
have a Yamaha dealer check and repair the ATV.
In addition, the differential gear oil must be
changed as follows at the intervals specified in the
periodic maintenance and lubrication chart.
1. Place the ATV on a level surface.
2. Place an oil pan under the differential gear
case to collect the used oil.
1. Final gear oil
2. Final gear oil filler bolt
3. Correct oil levelRecommended final gear oil:
See page 10-1.
Tightening torque:
Final gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
Tightening torque:
Final gear case guard bolt:
16 Nm (1.6 m·kgf, 11 ft·lbf)
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The differential gear case capacity is greater
than the recommended oil quantity, therefore
the oil level cannot be accurately checked fromthe oil filler hole.CAUTION:ECB00410Be sure no foreign material enters the differen-tial gear case.
6. Install the oil filler bolt, and then tighten it to the
specified torque.
7. Check the differential gear case for oil leak-
age. If oil is leaking, check for the cause.
EBU23470Coolant 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.EBU27940To check the coolant level
1. Place the ATV on a level surface.NOTE: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.NOTE:The coolant should be between the minimum andmaximum level marks. Recommended differential gear oil:
See page 10-1.
Oil quantity:
0.35 L (0.37 US qt) (0.31 Imp.qt)
Tightening torque:
Differential gear oil filler bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
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EBU23641Cleaning 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 more
frequently if you are riding in unusually wet or dusty
areas.NOTE: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. Remove the seat. (See page 4-12.)2. Remove the air filter case cover by unhooking
the holders.
3. Pull the air filter element out of the air filter
case.1. Air filter case check hose
1. Air filter case cover holder
2. Air filter case cover
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CAUTION:ECB00440Do not twist the sponge material when squeez-ing it.
7. Check the sponge material and replace it if
damaged.
8. Apply a quality foam air filter oil to the sponge
material.NOTE:The sponge material should be wet but not drip-ping.
9. Pull the sponge material over the air filter ele-
ment frame, and then install the lock plate.10. 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.
11. Install the seat.
NOTE: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 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.CAUTION:ECB00460
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
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EBU23940Adjusting the carburetor The carburetor should be checked and, if neces-
sary, adjusted at the intervals specified in the peri-
odic maintenance and lubrication chart. The
carburetor is an important part of the engine and
requires very sophisticated adjustment. Therefore,
most carburetor adjustments should be left to a
Yamaha dealer, who has the necessary profes-
sional knowledge and experience. The adjustment
described in the following section, however, may
be performed by the owner as part of routine main-
tenance.CAUTION:ECB00480The carburetor has been set and extensively
tested at the Yamaha factory. Changing these
settings without sufficient technical knowl-
edge may result in poor performance of ordamage to the engine.EBU24000Adjusting the engine idling speed The engine idling speed must be checked and, if
necessary, adjusted as follows at the intervals
specified in the periodic maintenance and lubrica-
tion chart.
NOTE:A diagnostic tachometer is needed to make thisadjustment.
1. Start the engine and warm it up.NOTE:The engine is warm when it quickly responds to thethrottle.
2. Attach the tachometer to the spark plug lead.
3. Check the engine idling speed and, if neces-
sary, adjust it to specification by turning the
throttle stop screw at the carburetor. To in-
crease the engine idling speed, turn the throt-
tle stop screw in direction (a), and to decrease
it, turn the screw in direction (b).
U3C262E0.book Page 36 Tuesday, June 26, 2007 3:36 PM