warning YAMAHA WOLVERINE 450 2008 Service Manual

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8

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.
NOTE:
The radiator fan is automatically switched on or
off according to the coolant temperature in the
radiator.
If the engine overheats, see page 8-56 for fur-ther instructions.EBU26441To change the coolant
WARNING
EWB01890Wait 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 pressureto escape before completely removing the cap.
1. Place the ATV on a level surface.
2. Remove panels C and D. (See page 8-9.)3. Place a container under the engine, and then
remove the coolant drain bolt. (Use a trough
or a similar object as shown to prevent coolant
from spilling on the footrest.)
1. Coolant drain bolt
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8 4. Pull off the lock plate, and then remove the
sponge material from the air filter element
frame.5. 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.
6. Squeeze the excess solvent out of the sponge
material and let it dry.
1. Air filter element
1. Air filter element frame
2. Sponge material
3. Air filter element lock plate
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8
WARNING
EWB02340Do not start the engine when cleaning the
spark arrester, otherwise it could cause injury
to the eyes, burns, carbon monoxide poison-
ing, possibly leading to death, and start a fire.
Always let the exhaust system cool prior totouching exhaust components.EBU23920V-belt cooling duct check hose If dust or water collects in the V-belt cooling duct
check hose, remove the hose and clean it.
EBU23930V-belt case drain plug After riding in water deep enough to allow it to en-
ter the V-belt case, remove this plug to drain the
water from the case.NOTE:If water drains from the V-belt case after removing
the plug, have a Yamaha dealer check the ATV asthe water may affect other engine parts.
1. V-belt cooling duct check hose (left front side of ATV)
1. V-belt case drain plug
U3C262E0.book Page 35 Tuesday, June 26, 2007 3:36 PM

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8

Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking performance.
Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and may
result in vapor lock.
Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid imme-
diately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.EBU24290Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the NOTE after the peri-
odic maintenance and lubrication chart. In addi-
tion, have the oil seals of the master cylinders and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
EBU24390Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have a
free play of zero mm (zero in) as shown. If the free
play is incorrect, have a Yamaha dealer check the
brake system.
WARNING
EWB02070Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:1. Brake lever free play
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83. Tighten the locknut.
If the correct free play cannot be obtained, have a
Yamaha dealer adjust it.
NOTE:When adjusting the rear brake lever free play:
Be sure not to step on the brake pedal.
Make sure the brake pedal does not move.Checking the brake pedal position
The top of the brake pedal should be positioned
67.0–77.0 mm (2.64–3.03 in) above the top of the
footboard bracket. If the brake pedal position is in-
correct, have a Yamaha dealer adjust it.
WARNING
EWB02070Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
After servicing:
Make sure the brakes operate smoothly and
that the free play is correct.
Make sure the brakes do not drag.
1. Locknut
2. Brake lever free play adjusting bolt
1. Brake pedal position
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8-45
83. Install the panel.
EBU24900Checking and lubricating the cables The operation and the condition of all control ca-
bles should be checked before each ride, and the
cables and cable ends should be lubricated if nec-
essary. If a cable is damaged or does not move
smoothly, have a Yamaha dealer check or replace
it.
WARNING
EWB02130Inspect 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 anaccident or injury.EBU28710Checking and lubricating the front and
rear brake levers The operation of the front and rear brake levers
should be checked before each ride, and the lever
pivots should be lubricated if necessary.
1. Brake light switch
2. Brake light switch adjusting nutRecommended lubricant:
Engine oil
Recommended lubricants:
Front brake lever:
Silicone grease
Rear brake lever:
Lithium-soap-based grease (all-purpose
grease)
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8
EBU25222Battery This model is equipped with a sealed-type (MF)
battery, which does not require any maintenance.
There is no need to check the electrolyte or to add
distilled water. Check and, if necessary, tighten the
battery lead connections.CAUTION:ECB00620Never attempt to remove the battery cell seals,as this would permanently damage the battery.
WARNING
EWB02160Battery 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 charge the battery
Have a Yamaha dealer charge the battery as soon
as possible if it seems to have discharged. Keep in
mind that the battery tends to discharge more
quickly if the ATV is equipped with optional electri-
cal accessories.
To store the battery
1. If the ATV will not be used for more than one
month, remove the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for more than two
months, check it at least once a month and ful-
ly charge it if necessary. Recommended lubricant:
Lithium-soap-based grease (all-purpose
grease)
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8
WARNING
EWB02171Always 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.EBU25541Replacing a headlight bulb If a headlight bulb burns out, replace it as follows.
1. Remove the headlight bulb holder cover at the
rear of the headlight by pulling it off.2. Remove the headlight bulb holder by pushing
it inward and turning it counterclockwise.
1. Headlight bulb holder cover
1. Headlight bulb holder
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83. Remove the defective bulb from the headlight
unit by pulling it out.
WARNING
EWB02220A headlight bulb is hot when it is on and imme-
diately after it is turned off. Wait for the bulb to
cool before touching or removing it. You can
be burned or a fire could start if the bulb touch-es something flammable.
4. Install a new headlight bulb into the headlight
unit by aligning the projection on the bulb with
the groove in the headlight unit.
CAUTION:ECB00650Do not touch the glass part of the headlight
bulb to keep it free from oil, otherwise the
transparency of the glass, the luminosity of the
bulb, and the bulb life will be adversely affect-
ed. Thoroughly clean off any dirt and finger-
prints on the headlight bulb using a clothmoistened with alcohol or thinner.
5. Install the headlight bulb holder by aligning the
projections with the holes in the headlight unit,
pushing it inward, and turning it clockwise until
it stops.
6. Install the headlight bulb holder cover at the
rear of the headlight.
1. Do not touch the glass part of the bulb.U3C262E0.book Page 51 Tuesday, June 26, 2007 3:36 PM

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8
EBU25740Troubleshooting 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
EWB02280Do 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.U3C262E0.book Page 55 Tuesday, June 26, 2007 3:36 PM