differential YAMAHA WOLVERINE 450 2008 Owners Manual

EBU17420
TABLE OF CONTENTS
SAFETY INFORMATION .............................. 1-1
LOCATION OF THE WARNING AND
SPECIFICATION LABELS ............................ 2-1
DESCRIPTION .............................................. 3-1
Left view ...................................................... 3-1
Right view.................................................... 3-1
Controls and instruments ............................ 3-2
INSTRUMENT AND CONTROL
FUNCTIONS .................................................. 4-1
Main switch ................................................ 4-1
Indicator lights and warning light ................ 4-2
Speedometer unit ....................................... 4-3
Handlebar switches .................................... 4-4
Throttle lever .............................................. 4-6
Speed limiter .............................................. 4-7
Front brake lever ........................................ 4-8
Brake pedal and rear brake lever ............... 4-8
Drive select lever ........................................ 4-9
Fuel tank cap .............................................. 4-9
Fuel ............................................................ 4-9
Fuel cock .................................................. 4-10Starter (choke) ..........................................4-12
Seat ..........................................................4-12
Storage compartment ...............................4-13
Adjusting the front shock absorber
assemblies ..............................................4-14
Adjusting the rear shock absorber
assembly .................................................4-16
PRE-OPERATION CHECKS ..........................5-1
Pre-operation check list ..............................5-1
Fuel .............................................................5-3
Engine oil ....................................................5-3
Final gear oil ...............................................5-3
Differential gear oil ......................................5-3
Coolant .......................................................5-3
Front and rear brakes .................................5-4
Throttle lever ...............................................5-5
Tires ............................................................5-5
Measuring the tire pressure ........................5-6
Tire wear limit .............................................5-7
Chassis fasteners .......................................5-7
Instruments, lights and switches .................5-7U3C262E0.book Page 1 Tuesday, June 26, 2007 3:36 PM

OPERATION .................................................. 6-1
Starting a cold engine ................................ 6-1
Starting a warm engine .............................. 6-3
Operating the drive select lever and
driving in reverse ...................................... 6-3
Engine break-in .......................................... 6-5
Parking ....................................................... 6-5
Parking on a slope ..................................... 6-5
Accessories and loading ............................ 6-6
RIDING YOUR ATV ...................................... 7-1
GETTING TO KNOW YOUR ATV............... 7-2
RIDE WITH CARE AND GOOD
JUDGEMENT ............................................ 7-2
BE CAREFUL WHERE YOU RIDE ............. 7-9
TURNING YOUR ATV .............................. 7-12
CLIMBING UPHILL ................................... 7-14
RIDING DOWNHILL.................................. 7-17
CROSSING A SLOPE............................... 7-18
CROSSING THROUGH SHALLOW
WATER ................................................... 7-19
RIDING OVER ROUGH TERRAIN ........... 7-22
SLIDING AND SKIDDING ......................... 7-22
WHAT TO DO IF... .................................... 7-23
WHAT TO DO... ........................................ 7-23PERIODIC MAINTENANCE AND MINOR
REPAIR ..........................................................8-1
Owner’s manual and tool kit .......................8-1
Periodic maintenance chart for the
emission control system ...........................8-3
General maintenance and lubrication
chart ..........................................................8-5
Removing and installing cowlings and
panels .......................................................8-9
Checking the spark plug ...........................8-15
Engine oil and oil filter cartridge ................8-17
Final gear oil .............................................8-22
Changing the differential gear oil ..............8-24
Coolant .....................................................8-26
Cleaning the air filter element ...................8-31
Cleaning the spark arrester ......................8-34
V-belt cooling duct check hose .................8-35
V-belt case drain plug ...............................8-35
Adjusting the carburetor ............................8-36
Adjusting the engine idling speed .............8-36
Adjusting the throttle cable free play .........8-37
Valve clearance ........................................8-38
Adjusting the drive select lever safety
system cable ...........................................8-38
Checking the front and rear brake pads ...8-38
Checking the brake fluid level ...................8-39
Changing the brake fluid ...........................8-41U3C262E0.book Page 2 Tuesday, June 26, 2007 3:36 PM

5-1
5
EBU19200
PRE-OPERATION CHECKS
EBU19222Pre-operation check list Before operating this ATV, be sure to check the items listed in the following table.
WARNING
EWB00480Always inspect your ATV each time you use it to make sure it is in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in the Owner’sManual. Failure to inspect increases the possibility of an accident or equipment damage.NOTE:The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the periodicmaintenance charts on page 8-3 to determine which service should be performed by a Yamaha dealer.
ITEM ROUTINE PAGE
FuelCheck fuel level in fuel tank, and add recommended fuel if neces-
sary.
Check fuel line for leakage. Correct if necessary.4-9, 5-3
Engine oilCheck oil level in engine, and add recommended oil to specified lev-
el if necessary.
Check ATV for oil leakage. Correct if necessary.5-3, 8-17
Final gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-22
Differential gear oilCheck ATV for oil leakage. Correct if necessary. 5-3, 8-24
CoolantCheck coolant level in reservoir, and add recommended coolant to
specified level if necessary.
Check cooling system for leakage. Correct if necessary.5-3, 8-26
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5-3
5
EBU19540Fuel Make sure that there is sufficient fuel in the tank.
(See page 4-9.)
WARNING
EWB00520
Do not overfill the fuel tank. Fuel expands
when it heats up. If the fuel tank is overfilled,
fuel could spill out due to heat from the en-
gine or the sun.
Be careful not to spill fuel, especially on the
engine or exhaust pipe which can cause a
fire and severe injury. Wipe up any spilled
fuel immediately.
Do not refuel right after the engine has been
running and is still very hot.
Be sure the fuel tank cap is closed securely.EBU19560Engine oil Make sure that the engine oil is at the specified lev-
el. Add oil as necessary. (See page 8-17.)EBU19590Final gear oil Make sure that the final gear oil is at the specified
level. Add oil as necessary. (See page 8-22.)
EBU19600Differential gear oil Make sure that the differential gear oil is at the
specified level. Add oil as necessary. (See page
8-24.)EBU19630Coolant Make sure that the coolant is at the specified level.
Add coolant as necessary. (See page 8-26.)NOTE:The coolant level must be checked on a cold en-
gine since the level varies with engine tempera-ture.
WARNING
EWB00510Wait 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 pressureto escape before completely removing the cap.
U3C262E0.book Page 3 Tuesday, June 26, 2007 3:36 PM

8-6
8
8*SwingarmCheck for excessive play, and correct if necessary.√√√
9*V- b e l tCheck for wear, cracks or other damage, and re-
place if necessary.√ √√√
10*Chassis fastenersMake sure that all nuts, bolts, and screws are
properly tightened.√√√√√
11*Shock absorber as-
sembliesCheck operation and correct if necessary.
Check for oil leakage and replace if necessary.√√√
12*Steering shaftLubricate with lithium-soap-based grease.√√√
13*Steering systemCheck operation and repair or replace if damaged.
Check toe-in and adjust if necessary.√√√√√
14*Engine mountCheck for cracks or other damage, and replace if
necessary.√√√
15*Axle bootsCheck for cracks or other damage, and replace if
necessary.√√√√√
16 Engine oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√ √√√
17Engine oil filter car-
tridgeReplace.√√√
18*Engine oil strainerClean.√√√
19 Differential gear oilChange.
Check ATV for oil leakage, and correct if neces-
sary.√√ 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
U3C262E0.book Page 6 Tuesday, June 26, 2007 3:36 PM

8-24
8
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)
U3C262E0.book Page 24 Tuesday, June 26, 2007 3:36 PM

8-25
83. Remove the differential gear oil filler bolt and
the differential gear oil drain bolt to drain the
oil from the differential gear case.
4. Install the drain bolt, and then tighten it to the
specified torque.
5. Add the specified amount of the recommend-
ed differential gear oil.
NOTE:
Do not exceed the specified differential gear oil
quantity when filling. Overfilling will cause the oil
to seep out of the breather hose during and after
riding.
1. Differential gear oil filler bolt
1. Differential gear oil drain boltTightening torque:
Differential gear oil drain bolt:
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
U3C262E0.book Page 25 Tuesday, June 26, 2007 3:36 PM

8-26
8

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)
U3C262E0.book Page 26 Tuesday, June 26, 2007 3:36 PM

10-2
10
Engine oil quantity:
Without oil filter cartridge replacement:
2.30 L (2.43 US qt) (2.02 Imp.qt)
With oil filter cartridge replacement:
2.40 L (2.54 US qt) (2.11 Imp.qt)Final gear oil:Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.23 L (0.24 US qt) (0.20 Imp.qt)Differential gear oil:Type:
SAE80 API GL-4 Hypoid gear oil
Quantity:
0.35 L (0.37 US qt) (0.31 Imp.qt)Cooling system:Coolant reservoir capacity (up to the maximum level mark):
0.25 L (0.26 US qt) (0.22 Imp.qt)
Radiator capacity (including all routes):
1.32 L (1.40 US qt) (1.16 Imp.qt)Air filter:Air filter element:
Wet elementFuel:Recommended fuel:
Regular unleaded gasoline only
Fuel tank capacity:
14.5 L (3.83 US gal) (3.19 Imp.gal)
Fuel reserve amount:
4.5 L (1.19 US gal) (0.99 Imp.gal)
Carburetor:Manufacturer:
MIKUNI
Type x quantity:
BSR33 x 1Spark plug (s):Manufacturer/model:
NGK/DR8EA
Spark plug gap:
0.6–0.7 mm (0.024–0.028 in)Clutch:Clutch type:
Wet, centrifugal automaticTransmission:Primary reduction system:
V-belt
Secondary reduction system:
Shaft drive
Secondary reduction ratio:
39/24 × 24/18 × 33/9 (7.944)
Transmission type:
V-belt automatic
Operation:
Left hand operation
Forward gear:
38/23 (1.652)
Reverse gear:
29/17 (1.706)Chassis:Frame type:
Steel tube frame
U3C262E0.book Page 2 Tuesday, June 26, 2007 3:36 PM

INDEX
AAccessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-31
Axle boots .................................................................... 8-44BBattery .......................................................................... 8-47
Brake fluid, changing .................................................... 8-41
Brake fluid level, checking ............................................ 8-39
Brake lever free play and brake pedal position (rear),
adjusting and checking .............................................. 8-42
Brake lever free play, checking the front ...................... 8-41
Brake lever, front ............................................................ 4-8
Brake levers, checking and lubricating ......................... 8-45
Brake light switches ..................................................... 8-44
Brake pads, checking the front and rear ...................... 8-38
Brake pedal and rear brake lever ................................... 4-8
Brake pedal, checking and lubricating ......................... 8-46
Brakes, front and rear .................................................... 5-4CCables, checking and lubricating ................................. 8-45
Carburetor, adjusting .................................................... 8-36
Chassis fasteners ........................................................... 5-7
Cleaning ......................................................................... 9-1
Coolant .................................................................. 5-3, 8-26
Coolant temperature warning light ................................. 4-2
Cowlings and panels, removing and installing ............... 8-9DDifferential gear oil ......................................................... 5-3Differential gear oil, changing ....................................... 8-24
Drive select lever ............................................................ 4-9
Drive select lever and driving in reverse ........................ 6-3
Drive select lever safety system cable, adjusting ......... 8-38
EEngine break-in .............................................................. 6-5
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-36
Engine oil ....................................................................... 5-3
Engine oil and oil filter cartridge ................................... 8-17
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-4FFinal gear oil .......................................................... 5-3, 8-22
Four-wheel-drive indicator .............................................. 4-3
Fuel ......................................................................... 4-9, 5-3
Fuel cock ...................................................................... 4-10
Fuel tank cap .................................................................. 4-9
Fuses, replacing ........................................................... 8-48HHandlebar switches ........................................................ 4-4
Headlight beam, adjusting ............................................ 8-52
Headlight bulb, replacing .............................................. 8-50IIdentification numbers .................................................. 11-1
Indicator lights and warning light .................................... 4-2
Instruments, lights and switches .................................... 5-7
U3C262E0.book Page 1 Tuesday, June 26, 2007 3:36 PM