brake YAMAHA YFZ450 2005 Owners Manual

EBU00150
1-CONTENTS
LOCATION OF THE WARNING
AND SPECIFICATION LABELS .............. 1-1
SAFETY INFORMATION ......................... 2-1
DESCRIPTION AND MACHINE
IDENTIFICATION .................................... 3-1
Identification number records ............... 3-3
Key identification number ..................... 3-5
Vehicle identification number ............... 3-5
Model label ........................................... 3-7
CONTROL FUNCTIONS ......................... 4-1
Main switch........................................... 4-1
Indicator and warning lights.................. 4-3
Handlebar switches .............................. 4-7
Throttle lever ...................................... 4-11
Speed limiter ...................................... 4-13
Clutch lever ........................................ 4-15
Brake lever ......................................... 4-17
Brake pedal ........................................ 4-17
Parking brake lever ............................ 4-19
Shift pedal .......................................... 4-21
Fuel tank cap ...................................... 4-21
1234
Fuel cock............................................ 4-23
Starter (choke) .................................. 4-25
Seat.................................................... 4-27
Front shock absorber adjustment ...... 4-29
Rear shock absorber adjustment ....... 4-39
PRE-OPERATION CHECKS ................... 5-1
Front and rear brakes .......................... 5-5
Fuel ...................................................... 5-9
Engine oil ........................................... 5-13
Coolant............................................... 5-15
Chain.................................................. 5-17
Throttle lever ...................................... 5-17
Fittings and fasteners......................... 5-19
Lights ................................................. 5-19
Switches............................................. 5-19
Tires ................................................... 5-21
How to measure tire pressure ............ 5-25
Tire wear limit..................................... 5-27
5
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OPERATION ............................................6-1
Starting a cold engine ...........................6-3
Starting a warm engine .........................6-9
Warming up...........................................6-9
Shifting ................................................6-11
To start out and accelerate .................6-13
To decelerate ......................................6-17
Engine break-in ...................................6-19
Parking ................................................6-23
Parking on a slope ..............................6-25
Accessories and loading .....................6-29
RIDING YOUR ATV..................................7-1
Getting to know your ATV .....................7-3
Ride with care and good judgement .....7-5
Be careful where you ride ...................7-27
Turning your ATV ................................7-41
Climbing uphill.....................................7-47
Riding downhill ....................................7-57
Crossing a slope .................................7-61
Crossing through shallow water ..........7-65
Riding over rough terrain ....................7-69
Sliding and skidding ............................7-71
What to do if ........................................7-75
What to do...........................................7-75
67
PERIODIC MAINTENANCE AND
ADJUSTMENT ......................................... 8-1
Owner’s manual and tool kit ................. 8-3
Periodic maintenance/lubrication.......... 8-7
Panel removal and installation............ 8-17
Engine oil and oil filter element........... 8-23
Cooling system ................................... 8-41
Changing the coolant.......................... 8-45
Spark plug inspection ......................... 8-53
Air filter element cleaning ................... 8-65
Carburetor adjustment ........................ 8-73
Idle speed adjustment ........................ 8-75
Valve clearance adjustment ............... 8-75
Throttle lever adjustment .................... 8-77
Front brake pad inspection ................. 8-79
Rear brake pad inspection.................. 8-81
Brake fluid level inspection ................. 8-83
Brake fluid replacement ...................... 8-87
Front brake lever free play.................. 8-89
Brake pedal height adjustment ........... 8-91
Parking brake adjustment ................... 8-93
Adjusting the rear brake light switch ... 8-97
Clutch lever free play adjustment ....... 8-99
Drive chain slack check .................... 8-101
Drive chain slack adjustment ............ 8-103
Lubricating the drive chain................ 8-107
Cable inspection and lubrication....... 8-111
8
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Brake pedal, brake lever and
clutch lever lubrication.................... 8-113
Front upper and lower arm pivot
lubrication ....................................... 8-117
Rear arm pivot lubrication ................ 8-119
Wheel removal ................................. 8-121
Wheel installation ............................. 8-123
Battery .............................................. 8-125
Battery maintenance ........................ 8-129
Fuse replacement............................. 8-131
Replacing a headlight bulb ............... 8-133
Headlight beam adjustment.............. 8-139
Tail/brake light bulb replacement ..... 8-141
Troubleshooting................................ 8-143
Troubleshooting chart....................... 8-147
CLEANING AND STORAGE ................... 9-1
A. Cleaning ........................................... 9-1
B. Storage ............................................ 9-7
SPECIFICATIONS ................................ 10-1
CONVERSION TABLE .......................... 11-1
91011U5TG61.book Page 3 Friday, April 2, 2004 11:28 AM

2-13

Always be careful when skidding or sliding.
Learn to safely control skidding or sliding by
practicing at low speeds and on level, smooth
terrain. On extremely slippery surfaces, such
as ice, go slowly and be very cautious in order
to reduce the chance of skidding or sliding out
of control.


Never operate an ATV in fast flowing water or
in water deeper than that recommended in this
manual. Remember that wet brakes may have
reduced stopping ability. Test your brakes after
leaving water. If necessary, apply them several
times to let friction dry out the linings.


Always use the size and type of tires specified
in this manual.


Always maintain proper tire pressure as de-
scribed in this manual.
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3-1
EBU00320
1-DESCRIPTION AND MACHINE
IDENTIFICATION1. Seat
2. Fuel tank cap
3. Radiator cap
4. Oil filter element
5. Brake pedal
6. Headlights
7. Fuel cock
8. Starter (choke)
9. Throttle stop screw
10. Fuse11. Tail/brake light
12. Coolant reservoir
13. Shift pedal
14. Engine oil tank
15. Clutch lever
16. Handlebar switches
17. Parking brake lever
18. Main switch
19. Throttle lever
20. Brake leverNOTE:_ The machine you have purchased may differ
slightly from those shown in the figures of this
manual. _
U5TG61.book Page 1 Friday, April 2, 2004 11:28 AM

4-17 1. Brake lever 2. Locknut 3. Adjusting bolt
a. Distance between brake lever and handlebar grip
1. Levier de frein 2. Contre-écrou 3. Boulon de réglage
a. Distance entre le levier de frein et la poignée
1. Palanca del freno 2. Contratuerca 3. Perno de ajuste
a. Distancia entre la palanca del freno y la empuñadura del
manillar
1. Brake pedal
1. Pédale de frein
1. Pedal del freno
EBU13860
Brake lever
The brake lever is located on the right handlebar.
Pull it toward the handlebar to apply the front
brake.
The brake lever is equipped with a position adjust-
ing bolt. To adjust the distance between the brake
lever and the handlebar grip, hold the lever away
from the handlebar so it does not contact the ad-
justing bolt, loosen the locknut, turn the adjusting
bolt, and then tighten the locknut.
EBU09890
Brake pedal
The brake pedal is located on the right side of the
machine. Push down on the pedal to apply the rear
brake.
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4-19 1. Parking brake lever (Locked position)
1. Levier de frein de stationnement (frein serré)
1. Palanca del freno de estacionamiento (posición de bloqueo)
1. Parking brake lever (Unlocked position)
1. Levier de frein de stationnement (frein relâché)
1. Palanca del freno de estacionamiento
(posición de desbloqueo)
EBU14072
Parking brake lever
Use the parking brake when you have to start the
engine or park the machine, especially on a slope.
To apply the parking brake, move the parking
brake lever in direction
a. To release the parking
brake, move the parking brake lever in
direction
b.
WARNING
_

Always set the parking brake before start-
ing the engine. The ATV could start mov-
ing unexpectedly if the parking brake is not
applied. This could cause loss of control or
a collision.


Always be sure you have released the
parking brake before you begin to ride. The
brake could overheat if you ride the ATV
without releasing the parking brake. You
could lose braking performance which
could cause an accident. You could also
wear out the brakes prematurely.
_
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5-1
EBU01130
1-PRE-OPERATION CHECKS
Before using this machine, check the following points:
ITEM ROUTINE PAGE
Front brakeCheck operation, lever free play, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7, 8-79,
8-83–8-89
Rear brakeCheck operation, fluid level and fluid leakage.
Fill with DOT 4 brake fluid if necessary.5-5–5-7,
8-81–8-87, 8-91
ClutchCheck operation, condition and lever free play. 8-99
Parking brakeCheck operation, condition and cable length. 8-93–8-95
FuelCheck fuel level.
Fill with fuel if necessary.5-9–5-11
Engine oilCheck oil level.
Fill with oil if necessary.5-13, 8-23–8-39
Coolant reservoirCheck coolant level in reservoir.
Fill with coolant if necessary.5-15–5-17,
8-41–8-51
Drive chainCheck chain slack and condition.
Adjust if necessary.5-17, 8-101–8-109
ThrottleCheck for proper throttle cable operation and free play. 5-17, 8-77
Wheels and tiresCheck tire pressure, wear and damage.5-21–5-27,
8-121–8-123
Fittings and fastenersCheck all fittings and fasteners. 5-19
Lights and switchesCheck for proper operation.5-19, 8-97,
8-133–8-141
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5-5
EBU11670
Front and rear brakes
Brake lever and brake pedal

Check that there is no free play in the brake le-
ver. If there is free play, have a Yamaha dealer
inspect the brake system.


Check for correct brake pedal height. (See
page 8-91.) If the pedal height is incorrect,
have a Yamaha dealer adjust it.


Check the operation of the brake lever and
brake pedal. They should move smoothly and
there should be a firm feeling when the brakes
are applied. If not, have a Yamaha dealer in-
spect the brake system.
Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See pages 8-83–8-87.)
Recommended brake fluid: DOT 4
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5-7
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or brake fluid reservoirs. Apply the
brakes firmly for one minute. If there is any leak-
age, have a Yamaha dealer inspect the brake sys-
tem.
Brake operation
Test the brakes at slow speed after starting out to
make sure they are working properly. If the brakes
do not provide proper braking performance, in-
spect the brake pads for wear. (See pages 8-79–
8-81.)
WARNING
_ Always check the brakes at the start of every
ride. Do not ride the ATV if you find any prob-
lem with the brakes or you could lose braking
ability, which could lead to an accident. If a
problem cannot be corrected by the adjust-
ment procedures provided in this manual,
have a Yamaha dealer check for the cause. _
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