brake pads YAMAHA YFZ450 2007 Owners Manual

Parking ...................................................... 6-5
Parking on a slope .................................... 6-6
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 ............ 7-8
TURNING YOUR ATV ............................. 7-12
CLIMBING UPHILL .................................. 7-14
RIDING DOWNHILL................................. 7-16
CROSSING A SLOPE.............................. 7-17
CROSSING THROUGH SHALLOW
WATER ..................................................7-18
RIDING OVER ROUGH TERRAIN .......... 7-20
SLIDING AND SKIDDING ........................ 7-20
WHAT TO DO IF... ................................... 7-21
WHAT TO DO... ....................................... 7-21
PERIODIC MAINTENANCE AND MINOR
REPAIR .......................................................... 8-1
Owner’s manual and tool kit ...................... 8-1
Periodic maintenance and lubrication
chart ........................................................ 8-3
Removing and installing the panel ............ 8-8
Checking the spark plug ............................ 8-9
Engine oil and oil filter element ............... 8-13
Coolant .................................................... 8-19Cleaning the air filter element .................. 8-23
Cleaning the spark arrester ..................... 8-26
Adjusting the carburetor ........................... 8-28
Checking the engine idling speed ............ 8-29
Adjusting the throttle cable free play ........ 8-29
Valve clearance ....................................... 8-30
Checking the front and rear brake pads .. 8-30
Checking the brake fluid level .................. 8-31
Changing the brake fluid .......................... 8-34
Checking the front brake lever free play .. 8-34
Checking the brake pedal position ........... 8-35
Adjusting the parking brake free play ...... 8-36
Brake light switches ................................. 8-37
Adjusting the clutch lever free play .......... 8-38
Drive chain slack ...................................... 8-39
Lubricating the drive chain ....................... 8-41
Checking and lubricating the cables ........ 8-42
Checking and lubricating the brake and
clutch levers ........................................... 8-42
Checking and lubricating the brake and
shift pedals ............................................. 8-43
Checking the wheel bearings ................... 8-43
Lubricating the swingarm pivots .............. 8-44
Lubricating the upper and lower arm
pivots ..................................................... 8-44
Battery ..................................................... 8-45
Replacing the fuse ................................... 8-46
Replacing a headlight bulb ...................... 8-47
Adjusting a headlight beam ..................... 8-49

5-1
1
2
3
45
6
7
8
9
10
11

EBU19200
PRE-OPERATION CHECKS
EBU19220
Pre-operation check list
Before operating this ATV, be sure to check the items listed in the following table.
NOTE:

The maintenance of some items in the table has to be performed by a Yamaha dealer. Refer to the “Periodic
maintenance and lubrication chart” on page 8-3 to determine which service should be performed by a
Yamaha dealer.
ITEM ROUTINE PAGE
Fuel


Check fuel level in fuel tank, and add recommended fuel if neces-
sary.

Check fuel line for leakage. Correct if necessary.4-8, 5-4
Engine oil

Check oil level in engine, and add recommended oil to specified
level if necessary.

Check ATV for oil leakage. Correct if necessary.5-4, 8-13
Coolant

Check coolant level in reservoir, and add recommended coolant to
specified level if necessary.

Check cooling system for leakage. Correct if necessary.5-4, 8-19
Front brake

Check operation. If soft or spongy, have Yamaha dealer bleed
hydraulic system.

Check brake pads for wear, and replace if necessary.

Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.

Check hydraulic system for leakage. Correct if necessary.5-4, 8-30, 8-31, 8-34

5-2
1
2
3
45
6
7
8
9
10
11

Rear brake

Check operation. If soft or spongy, have Yamaha dealer bleed
hydraulic system.

Check lever free play, and adjust if necessary.

Check brake pads for wear, and replace if necessary.

Check brake fluid level in reservoir, and add recommended brake
fluid to specified level if necessary.

Check hydraulic system for leakage. Correct if necessary.5-4, 8-30, 8-31, 8-35
Clutch

Check operation, and correct if necessary.

Lubricate cable if necessary.

Check lever free play, and adjust if necessary.8-38
Throttle lever

Make sure that operation is smooth. Lubricate cable and lever hous-
ing if necessary.

Check cable free play, and adjust if necessary.5-5, 8-29
Control cables

Make sure that operation is smooth. Lubricate if necessary. 8-42
Drive chain

Check chain slack, and adjust if necessary.

Check chain condition. Lubricate if necessary.5-5, 8-39, 8-41
Wheels and tires

Check wheel condition, and replace if damaged.

Check tire condition and tread depth. Replace if necessary.

Check air pressure. Correct if necessary.5-5, 5-6, 5-7
Brake and shift pedals

Make sure that operation is smooth. Lubricate pedal pivoting points
if necessary.8-43
Brake and clutch levers

Make sure that operation is smooth. Lubricate lever pivoting points
if necessary.8-42
Chassis fasteners

Make sure that all nuts, bolts and screws are properly tightened. 5-8
Instruments and switches

Check operation, and correct if necessary. 5-8
Instruments, lights and
switches

Check operation, and correct if necessary. 5-8
ITEM ROUTINE PAGE

5-5
1
2
3
45
6
7
8
9
10
11

Brake fluid level
Check the brake fluid level. Add fluid if necessary.
(See page 8-31.)
Brake fluid leakage
Check to see if any brake fluid is leaking out of the
pipe joints or master cylinder. Apply the brakes
firmly for one minute. If there is any leaking, have
the ATV checked by a Yamaha dealer.
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, check
the brake pads for wear. (See page 8-30.)
WARNING

EWB00580
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.
EBU19761
Throttle lever
Check the operation of the throttle lever. It must
open smoothly and spring back to the idle position
when released. Have a Yamaha dealer correct if
necessary.
EBU19770
Drive chain
Check the condition of the drive chain and check
the drive chain slack. Lubricate and adjust the
drive chain as necessary. (See page 8-39.)
EBU19791
Tires
WARNING

EWB00601
Use of improper tires on this ATV, or operation
of this ATV with improper or uneven tire pres-
sure, may cause loss of control, increasing
your risk of accident.
Pay attention to the following.

The tires listed below have been approved
by Yamaha Motor Co., Ltd. for this model.
Other tire combinations are not recommend-
Recommended brake fluid:
DOT 4

8-3
1
2
3
4
5
6
78
9
10
11

EBU22402
Periodic maintenance and lubrication chart
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 inter-
vals. However, keep in mind that if the ATV isn’t used for a long period of time, the month maintenance
intervals should be followed.

Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth136612
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 3001
*
Fuel line


Check fuel hoses for cracks or other damage, and
replace if necessary.
√√√
2 Spark plug

Check condition and clean, regap, or replace if
necessary.
√√√√√
3
*
Valves


Check valve clearance and adjust if necessary.
√ √√√
4 Air filter element

Clean and replace if necessary.Every 20–40 hours (more often in wet or
dusty areas)
5
*
Clutch

Check operation and adjust if necessary.
√ √√√
6
*
Front brake


Check operation and correct if necessary.

Check fluid level and ATV for fluid leakage, and
correct if necessary.
√√√√√

Replace brake pads. Whenever worn to the limit

8-4
1
2
3
4
5
6
78
9
10
11

7
*
Rear brake

Check operation and correct if necessary.

Check brake lever free play and adjust if neces-
sary.

Check fluid level and ATV for fluid leakage, and
correct if necessary.
√√√√√

Replace brake pads. Whenever worn to the limit
8
*
Brake hoses

Check for cracks or other damage, and replace if
necessary.
√√√√

Replace. Every 4 years
9
*
Parking brake

Check operation and adjust if necessary.
√√√√√
10
*
Wheels


Check runout and for damage, and replace if nec-
essary.
√ √√√
11
*
Tires


Check tread depth and for damage, and replace if
necessary.

Check air pressure and balance, and correct if
necessary.
√ √√√
12
*
Wheel bearings


Check for looseness or damage, and replace if
necessary.
√ √√√
13
*
Swingarm pivots


Check operation and for excessive play, and
replace bearings if necessary.

Lubricate with molybdenum disulfide grease.
√√√
14
*
Upper and lower
arm pivots

Lubricate with lithium-soap-based grease.
√√√
NO. ITEMCHECK OR MAINTENANCE
JOBINITIAL EVERY
Whichev-
er comes
firstmonth 1 3 6 6 12
km
(mi)320
(200)1200
(750)2400
(1500)2400
(1500)4800
(3000)
hours 20 75 150 150 300

8-30
1
2
3
4
5
6
78
9
10
11

EBU24060
Valve clearance
The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24130
Checking the front and rear brake pads
The front and rear brake pads must be checked for
wear at the intervals specified in the periodic main-
tenance and lubrication chart.
EBU27711
Front brake pads
Each brake pad is provided with wear indicator
grooves, which allow you to check the brake pad
wear without having to disassemble the brake. To
check the brake pad wear, check the wear indica-
tor grooves. If a brake pad has worn to the point
that the wear indicator grooves are almost in con-
tact with the disc plate, have a Yamaha dealer re-
place the brake pads as a set.
NOTE:

The wheels need to be removed to check the
brake pads. (See page 8-50.)
EBU27721
Rear brake pads
Each brake pad is provided with wear indicator
grooves, which allow you to check the brake pad
wear without having to disassemble the brake. To
check the brake pad wear, check the wear indica-
tor grooves. If a brake pad has worn to the point
that the wear indicator grooves are almost in con-
tact with the disc plate, have a Yamaha dealer re-
1. Wear indicator groove
1

8-31
1
2
3
4
5
6
78
9
10
11

place the brake pads as a set.
EBU26831
Checking the brake fluid level
Insufficient brake fluid may allow air to enter the
brake system, possibly causing it to become inef-
fective.
Before riding, check that the brake fluid is above
the minimum level mark and replenish if neces-
sary. A low brake fluid level may indicate worn
brake pads and/or brake system leakage. If the
brake fluid level is low, be sure to check the brake
pads for wear and the brake system for leakage.
Front brake
1. Wear indicator groove
1

1. Minimum level mark1

8-34
1
2
3
4
5
6
78
9
10
11


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.
EBU24290
Changing 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.
EBU24390
Checking 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

EWB02070
Operating with improperly serviced or adjust-
ed brakes could cause loss of braking ability,
which could lead to an accident.
1. Brake lever free play
1

INDEX
A
Accessories and loading ................................................ 6-6
Air filter element, cleaning ............................................ 8-23
B
Battery .......................................................................... 8-45
Brake and clutch levers, checking and lubricating ....... 8-42
Brake and shift pedals, checking and lubricating ......... 8-43
Brake fluid, changing.................................................... 8-34
Brake fluid level, checking............................................ 8-31
Brake lever ..................................................................... 4-6
Brake lever free play, checking the front ...................... 8-34
Brake light switches ..................................................... 8-37
Brake pads, checking the front and rear ...................... 8-30
Brake pedal .................................................................... 4-6
Brake pedal position, checking .................................... 8-35
Brakes, front and rear .................................................... 5-4
C
Cables, checking and lubricating ................................. 8-42
Carburetor, adjusting.................................................... 8-28
Chassis fasteners........................................................... 5-8
Cleaning ......................................................................... 9-1
Clutch lever .................................................................... 4-5
Clutch lever free play, adjusting ................................... 8-38
Coolant ................................................................. 5-4
,
8-19
Coolant temperature warning light ................................. 4-2
D
Drive chain ..................................................................... 5-5
Drive chain, lubricating ................................................. 8-41
Drive chain slack .......................................................... 8-39
E
Engine break-in .............................................................. 6-5
Engine, cold start ........................................................... 6-1
Engine idling speed ...................................................... 8-29
Engine oil ....................................................................... 5-4
Engine oil and oil filter element .................................... 8-13
Engine, starting a warm ................................................. 6-3
Engine stop switch ......................................................... 4-3
F
Fuel ........................................................................ 4-8
,
5-4
Fuel cock ........................................................................ 4-9
Fuel tank cap.................................................................. 4-8
Fuse, replacing............................................................. 8-46
H
Handlebar switches ........................................................ 4-3
Headlight beam, adjusting............................................ 8-49
Headlight bulb, replacing.............................................. 8-47
I
Identification numbers .................................................. 11-1
Indicator light and warning light...................................... 4-2
Instruments, lights and switches .................................... 5-8