maintenance YAMAHA YFZ450 2012 User Guide

8-5
8
EBU21865General maintenance and lubrication chart TIP
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. ITEM CHECK OR MAINTENANCE
JOB INITIAL
EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320
1 Air filter element Clean and replace if necessary. Every 20
–40 hours (more often in wet or
dusty areas)
2 *Clutch Check operation and adjust if necessary. √ √√√
3 *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
4 *Rear 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
U1PD60E0.book Page 5 Monday, June 13, 2011 2:57 PM

8-6
8
5*Brake hoses 
Check for cracks or other damage, and replace if
necessary. √√√√
 Replace. Every 4 years
6 *Parking brake Check operation and adjust if necessary. √√√√√
7 *Wheels 
Check runout and for damage, and replace if nec-
essary. √ √√√
8 *Tires 
Check tread depth and for damage, and replace if
necessary.
 Check air pressure and balance, and correct if
necessary. √ √√√
9 *Wheel hub bearings 
Check for looseness or damage, and replace if
necessary. √ √√√
10 *Swingarm pivots 
Check operation and for excessive play, and re-
place bearings if necessary.
 Lubricate with lithium-soap-based grease. √√√
11 *Upper and lower
arm pivots

Lubricate with lithium-soap-based grease. √√√
12 Drive chain 
Check chain slack and adjust if necessary.
 Check rear wheel alignment and correct if neces-
sary.
 Clean and lubricate. √√√√√
13 *Drive chain rollers Check for wear and replace if necessary. √√√
NO. ITEM
CHECK OR MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U1PD60E0.book Page 6 Monday, June 13, 2011 2:57 PM

8-7
8
14*Chassis fasteners 
Make sure that all nuts, bolts, and screws are
properly tightened. √√√√√
15 *Shock absorber as-
semblies 
Check operation and correct if necessary.
 Check for oil leakage and replace if necessary. √√√
16 *Rear suspension re-
lay arm and con-
necting arm
pivoting points 
Check operation and correct if necessary. √√√√
17 *Steering shaft Lubricate with lithium-soap-based grease. √√√
18 *Steering system 
Check operation and repair or replace if damaged.
 Check toe-in and adjust if necessary. √√√√√
19 *Engine mount 
Check for cracks or other damage, and replace if
necessary. √√√
20 Engine oil 
Change.
 Check ATV for oil leakage, and correct if neces-
sary. √ √√√
21 Engine oil filter ele-
ment

Replace. √√√
22 Cooling system 
Check coolant level and ATV for coolant leakage,
and correct if necessary. √√√√√
 Replace coolant. Every 2 years
NO. ITEM
CHECK OR MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U1PD60E0.book Page 7 Monday, June 13, 2011 2:57 PM

8-8
8
EBU23071TIP
Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy or
muddy areas, or at full-throttle.
Hydraulic brake service
Regularly check and, if necessary, correct the brake fluid level.
 Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
 Replace the brake hoses every four years and if cracked or damaged.23 *Moving parts and
cables 
Lubricate. √√√√
24 *Throttle lever 
Check operation.
 Check throttle lever free play, and adjust if neces-
sary.
 Lubricate cable and lever housing. √√√√√
25 *Front and rear brake
switches 
Check operation and correct if necessary. √√√√√
26 *Lights and switches 
Check operation and correct if necessary.
 Adjust headlight beams. √√√√√
NO. ITEM
CHECK OR MAINTENANCE
JOB INITIAL EVERY
Whichev- er comes first month136612
km
(mi) 320
(200) 1300
(800) 2500
(1600) 2500
(1600) 5000
(3200)
hours 20 80 160 160 320U1PD60E0.book Page 8 Monday, June 13, 2011 2:57 PM

8-9
8
EBU23080Removing and installing the panel The panel shown needs to be removed to perform
some of the maintenance jobs described in this
chapter. Refer to this section each time the panel
needs to be removed and installed.EBU23180Panel A
To remove the panel1. Remove the seat. (See page 4-12.)
2. Remove the quick fastener screw and thebolts, and then remove the panel by pulling it
out from the front of the ATV.1. Panel A
1
1. Quick fastener screw
2. Bolt
1. Bolt
1
2
1
U1PD60E0.book Page 9 Monday, June 13, 2011 2:57 PM

8-10
8To install the panel
1. Place the panel in the original position, and
then install the quick fastener screw and the
bolts. 2. Install the seat.
EBU23245Checking the spark plug The spark plug is an important engine component,
which is easy to check. Since heat and deposits
will cause any spark plug to slowly erode, the spark
plug should be removed and checked in accor-
dance with the periodic maintenance and lubrica-
tion chart. In addition, the condition of the spark
plug can reveal the condition of the engine.1. Projection
2. Slot
1
1
2
2
U1PD60E0.book Page 10 Monday, June 13, 2011 2:57 PM

8-14
8To install the spark plug
1. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any
grime from the spark plug threads.
2. Install the spark plug with the spark plug wrench, and then tighten it to the specified
torque.
TIPIf a torque wrench is not available when installing
the spark plug, a good estimate of the correct
torque is 1/4 –1/2 turn past finger tight. However,
the spark plug should be tightened to the specified
torque as soon as possible.3. Install the spark plug cap.
4. Place the fuel tank in the original position, and then install the bolt.
5. Remove the fuel tank cap by turning it coun- terclockwise.
6. Place the panel in the original position. 7. Install the fuel tank cap by turning it clockwise.
8. Install the bolts and the quick fastener screws.
9. Install the seat.
EBU23307Engine oil and oil filter element The engine oil level should be checked before
each ride. In addition, the oil must be changed and
the oil filter element replaced at the intervals spec-
ified in the periodic maintenance and lubrication
chart.
Tightening torque:
Spark plug:13 Nm (1.3 m ·kgf, 9.4 ft ·lbf)1. Projection
2. Slot
2 1
U1PD60E0.book Page 14 Monday, June 13, 2011 2:57 PM

8-20
8a higher quality than specified. In addition,
do not use oils labeled
“ENERGY CONSERV-
ING II” or higher.

Make sure that no foreign material enters the
crankcase.15. Start the engine, and then let it idle for several
minutes while checking it for oil leakage. If oil
is leaking, immediately turn the engine off and
check for the cause.
16. Turn the engine off, and then check the oil lev- el and correct it if necessary.
17. Install the engine guard by installing the bolts, and then tighten them to the specified torque.
NOTICE: Be sure to apply LOCTITE
® to the
engine guard bolts before installing them.
[ECB00371] EBU23470
Coolant 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.EBU27942To check the coolant level
1. Place the ATV on a level surface.TIPThe 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.TIPThe coolant should be between the minimum and
maximum level marks.
Tightening torque:Engine guard bolt:7 Nm (0.7 m ·kgf, 5.1 ft ·lbf)
U1PD60E0.book Page 20 Monday, June 13, 2011 2:57 PM

8-24
813. Remove the radiator cap to check the coolant
level in the radiator. If it is low, add sufficient
coolant until it reaches the top of the radiator,
and then install the radiator cap.
14. Start the engine, and then check for coolant leakage.
TIPIf any leakage is found, have a Yamaha dealer
check the cooling system.15. Install the panel.EBU23707Cleaning the air filter element The air filter element should be cleaned at the in-
tervals specified in the periodic maintenance and
lubrication chart. Clean or, if necessary, replace
the air filter element more frequently if you are
riding in unusually wet or dusty areas.TIPThere is a check hose at the bottom of the air filter
case. If dust or water collects in this hose, empty
the hose and clean the air filter element and air fil-
ter case.
1. Place the ATV on a level surface.
2. Remove the seat. (See page 4-12.)
3. Remove the air filter case cover by unhookingthe holders.1. Air filter case check hose
1
U1PD60E0.book Page 24 Monday, June 13, 2011 2:57 PM

8-28
817. Install the seat.
TIPThe air filter element should be cleaned every 20
–
40 hours. It should be cleaned and lubricated more
often if the ATV is operated in extremely dusty ar-
eas. Each time the air filter element maintenance
is performed, check the air inlet of the air filter case
for obstructions. Check the air filter case rubber
joint to the carburetor fittings and the rubber joint
manifold fittings for an air-tight seal. Tighten all fit-
tings securely to avoid the possibility of unfiltered
air entering the engine.EBU27703Cleaning the spark arrester Select a well-ventilated area free of combustible
materials and make sure the exhaust and muffler
are cool. 1. Remove the tailpipe bolt. 2. Remove the tailpipe by pulling it out of the
muffler.
3. Tap the tailpipe lightly, and then use a wire brush to remove any carbon deposits from the
spark arrester portion of the tailpipe and inside
of the tailpipe housing.
1. Tailpipe bolt
1
U1PD60E0.book Page 28 Monday, June 13, 2011 2:57 PM