oil 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
U5TG61.book Page 1 Friday, April 2, 2004 11:28 AM

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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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. _
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4-37
NOTE:_ Although the total number of clicks of a damping
force adjusting mechanism may not exactly match
the above specifications due to small differences
in production, the actual number of clicks always
represents the entire adjusting range. To obtain a
precise adjustment, it would be advisable to check
the number of clicks of each damping force adjust-
ing mechanism and to modify the specifications as
necessary. _
WARNING
_

Suspension components become hot dur-
ing operation. Never touch the compres-
sion damping force adjusting screw, the
rebound damping force adjusting screw or
the oil reservoir with your bare hand or
skin until suspension components have
cooled.


Always adjust the shock absorbers on the
left and right side to the same setting.
_
U5TG61.book Page 37 Friday, April 2, 2004 11:28 AM

4-51
CAUTION:_ Never turn an adjusting mechanism beyond
the minimum and maximum settings. _
WARNING
_ Suspension components become hot during
operation. Never touch the compression
damping force adjusting screw, the rebound
damping force adjusting screw or the oil reser-
voir with your bare hand or skin until suspen-
sion components have cooled. _
U5TG61.book Page 51 Friday, April 2, 2004 11:28 AM

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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5-13
EBU10842
Engine oil
Make sure the engine oil is at the specified level.
Add oil as necessary. (See page 8-23.)CAUTION:_

In order to prevent clutch slippage (since
the engine oil also lubricates the clutch),
do not mix any chemical additives. Do not
use oils with a diesel specification of “CD”
or oils of a higher quality than specified. In
addition, do not use oils labeled “ENERGY
CONSERVING II” or higher.


Make sure that no foreign material enters
the crankcase.
_
Recommended engine oil type and quantity:
See page 10-2.
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8-7
EBU02621
PERIODIC MAINTENANCE/LUBRICATION
NOTE:_

For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.


For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance in-
tervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte-
nance intervals should be followed.
_
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
Valves*Check valve clearance.
Adjust if necessary.
Cooling systemCheck for coolant leakage.
Repair if necessary.
Replace coolant every 24 months.Spark plugCheck condition.
Adjust gap and clean.
Replace if necessary.Air filter elementClean.
Replace if necessary.Every 20–40 hours
(More often in wet or dusty areas.)
Carburetor*Check starter (choke) operation.
Adjust engine idling speed.Crankcase breather
system*Check breather hose for cracks or damage.
Replace if necessary.Exhaust system*Check for leakage.
Tighten if necessary.
Replace gasket if necessary.Fuel line*Check fuel hose for cracks or damage.
Replace if necessary.Engine oil
Replace (Warm engine before draining).U5TG61.book Page 7 Friday, April 2, 2004 11:28 AM

8-8 * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Engine oil filter element
Replace.Drive chain
Check and adjust slack/alignment/clean/lube.Front brake*Check free play/operation/fluid leakage/
See NOTE Page 8-9.
Correct if necessary.Rear brake*Check operation/fluid leakage/See NOTE Page 8-9.
Correct if necessary.Clutch*Check operation.
Adjust if necessary.Wheels*Check balance/damage/runout.
Replace if necessary.Wheel bearings*Check bearing assemblies for looseness/damage.
Replace if damaged.Steering system*Check operation.
Repair if damaged.
Check toe-in.
Adjust if necessary.Front and rear
suspension*Check operation.
Correct if necessary.Upper and lower arm
pivot and steering shaft*Lubricate every 6 months with lithium-soap-based grease.Rear arm pivot*
Lubricate every 6 months with lithium-soap-based grease.Fittings and fasteners*Check all chassis fittings and fasteners.
Correct if necessary.Lights and switches*Check operation.
Adjust headlight beams.
ITEM ROUTINEWhichever
comes firstINITIAL EVERY
month136612
km
(mi)320
(200)1,200
(750)2,400
(1,500)2,400
(1,500)4,800
(3,000)
hours 20 75 150 150 300
U5TG61.book Page 8 Friday, April 2, 2004 11:28 AM

8-9
NOTE:

Recommended brake fluid: DOT4


Brake fluid replacement:
When disassembling the master cylinders or calipers, replace the brake fluid. Normally check the
brake fluid level and add fluid as required.
On the inner parts of the master cylinders and calipers, replace the oil seals every two years.
Replace the brake hoses every four years, or if cracked or damaged.
U5TG61.book Page 9 Friday, April 2, 2004 11:28 AM