warning YAMAHA YFZ450 2005 Repair Manual

8-67 1. Wing bolt 2. Air filter element
1. Boulon papillon 2.Élément du filtre à air
1. Perno de aletas 2. Elemento del filtro de aire
1. Air filter element 2. Frame
1.Élément du filtre à air 2. Armature
1. Elemento del filtro de aire 2. Bastidor
3. Remove the air filter element by removing the
wing bolt.
4. Remove the air filter element from its frame.
5. Wash the air filter element gently but thor-
oughly in solvent.
WARNING
_ Always use parts cleaning solvent to clean the
air filter element. Never use low flash point sol-
vents or gasoline to clean the air filter element
because the engine could catch fire or ex-
plode. _
U5TG61.book Page 67 Friday, April 2, 2004 11:28 AM

8-89 a. Brake lever free play
a. Jeu du levier de frein
a. Juego de la palanca de freno
EBU11880
Front brake lever free play
The front brake lever should have a free play of
zero mm at the lever end. If not, have a Yamaha
dealer check the brake system.
WARNING
_ Operating 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.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5TG61.book Page 89 Friday, April 2, 2004 11:28 AM

8-91 a. Brake pedal position
a. Position de la pédale de frein
a. Posición del pedal del freno
EBU10790
Brake pedal height adjustment
The top of the brake pedal should be positioned
11.7 mm below the top of the footrest. If not, have
a Yamaha dealer adjust it.
WARNING
_ Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident. After servic-
ing:

Make sure the brakes operate smoothly
and that the brake pedal position is cor-
rect.


Make sure the brakes do not drag.


Make sure the brakes are not spongy. All
air must be bled from the brake system.
Replacement of brake components requires
professional knowledge. These procedures
should be performed by a Yamaha dealer.
_
U5TG61.book Page 91 Friday, April 2, 2004 11:28 AM

8-95
5. Screw in the adjusting bolt at the rear brake
caliper by hand until it feels tight, then screw it
out 1/8 turn. Tighten the locknut to the speci-
fied torque.CAUTION:_ When tightening the locknut, hold the adjust-
ing bolt with a wrench so that the adjusting
bolt does not turn together with the locknut. _
WARNING
_ Operating with improperly adjusted brakes
could cause the brakes to malfunction, result-
ing in reduced braking performance. This
could increase the chance of a collision or ac-
cident. After adjusting the parking brake, block
the rear of the machine off the ground and spin
the rear wheels. Check to make sure there is
no brake drag. If brake drag is noticed, perform
the adjustment again. _
Tightening torque:
Locknut:
16 Nm (1.6 m·kgf)
U5TG61.book Page 95 Friday, April 2, 2004 11:28 AM

8-111
EBU05700
Cable inspection and lubrication
WARNING
_ Inspect cables frequently and replace if dam-
aged. Corrosion can result when the outer cov-
ering of control cables becomes damaged.
Cables can also become frayed or kinked. Op-
eration of controls could be restricted, which
could cause an accident or injury. _Lubricate the inner cables and the cable ends. If
the cables do not operate smoothly, ask a Yamaha
dealer to replace them.
Recommended lubricant:
Engine oil
U5TG61.book Page 111 Friday, April 2, 2004 11:28 AM

8-127
WARNING
_ Battery electrolyte is poisonous and danger-
ous, causing severe burns, etc. It contains sul-
furic acid. Avoid contact with skin, eyes or
clothing.
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
ignition away. Ventilate when charging or us-
ing in an enclosed space. Always shield your
eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN. _
U5TG61.book Page 127 Friday, April 2, 2004 11:28 AM

8-131 1. Fuse 2. Spare fuse
1. Fusible 2. Fusible de rechange
1. Fusible 2. Fusible de repuesto
EBU03910
Fuse replacement
1. The fuse case is located under the seat.
2. If the fuse is blown, turn off the main switch
and install a new fuse of the specified amper-
age. Then turn on the switches. If the fuse im-
mediately blows again, consult a Yamaha
dealer.
WARNING
_ Always use a fuse of the specified rating. Nev-
er use a material in place of the proper fuse. An
improper fuse can cause damage to the electri-
cal system which could lead to a fire. _CAUTION:_ To prevent accidental short-circuiting, turn off
the main switch when checking or replacing a
fuse. _
Specified fuse: 15.0 A
U5TG61.book Page 131 Friday, April 2, 2004 11:28 AM

8-135 1. Headlight bulb holder
1. Fixation d’ampoule de phare
1. Portabombillas del faro
1. Do not touch the glass part of the bulb.
1. Ne pas toucher le verre de l’ampoule.
1. Ne tocar la parte de cristal de la bombilla.
4. Push the headlight bulb holder in and turn it
counterclockwise to remove.
5. Remove the defective bulb and replace it with
a new bulb.
WARNING
_ Do not touch a headlight bulb when it is on or
immediately after it is turned off. You can be
burned or a fire could start if the bulb touches
something flammable. Wait for the bulb to cool
before touching or removing it. _CAUTION:_ Do 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 cloth
moistened with alcohol or thinner. _
U5TG61.book Page 135 Friday, April 2, 2004 11:28 AM

8-145
WARNING
_ Do not smoke when checking the fuel system.
Fuel can ignite or explode, causing severe in-
jury or property damage. Make sure there are
no open flames or sparks in the area, including
pilot lights from water heaters or furnaces. _
U5TG61.book Page 145 Friday, April 2, 2004 11:28 AM

8-148
Engine overheatingNOTE:_ If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is
changed to the recommended coolant as soon as possible. _
WARNING
_ 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 put a thick rag over the cap when opening.
Allow any remaining pressure to escape before completely removing the cap. _ Wait until the
engine has cooled.
Check the coolant level in the
coolant reservoir and/or radiator.
Level is OK.Level is low, check the
cooling system for leakage.
No
leakage.Leakage.
Ask a Yamaha dealer to inspect
and repair the cooling system.Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and/or repair the cooling system.
U5TG61.book Page 148 Friday, April 2, 2004 11:28 AM