YAMAHA YFZ450 2012 Manual Online

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EBU28783
PERIODIC MAINTENANCE AND ADJUSTMENT
EBU21674Periodic inspection, adjustment, and lubrication
will keep your vehicle in the safest and most effi-
cient condition possible. Safety is an obligation of
the vehicle owner/operator. The most important
points of vehicle inspection, adjustment, and lubri-
cation are explained on the following pages.
WARNING
EWB01841Failure to properly maintain the vehicle or per-
forming maintenance activities incorrectly may
increase your risk of injury or death during ser-
vice or while using the vehicle. If you are not fa-
miliar with vehicle service, have a Yamaha
dealer perform the service.
WARNING
EWB02562Turn off the engine when performing mainte-
nance unless otherwise specified.
A running engine has moving parts that can
catch on body parts or clothing and electri-
cal parts that can cause shocks or fires.

Running the engine while servicing can lead
to eye injury, burns, fire, or carbon monoxide
poisoning - possibly leading to death. See
page 2-3 for more information about carbon
monoxide.
WARNING
EWB02690Brake discs, calipers, drums, and linings can
become very hot during use. To avoid possible
burns, let brake components cool before
touching them.The intervals given in the periodic maintenance
charts should be considered as a general guide
under normal riding conditions. However, DE-
PENDING ON THE WEATHER, TERRAIN, GEO-
GRAPHICAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTERVALS MAY
NEED TO BE SHORTENED.
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EBU27111Owner’s manual and tool kit Be sure to put this owner ’s manual in the plastic
bag and to always carry it as well as the owner ’s
tool kit and the low-pressure tire gauge in their re-
spective compartments under the seat.
The service information included in this manual
and the tools provided in the owner ’s tool kit are in-
tended to assist you in the performance of preven-
tive maintenance and minor repairs. However, additional tools such as a torque wrench may be
necessary to perform certain maintenance work
correctly.
TIPIf you do not have the tools or experience required
for a particular job, have a Yamaha dealer perform
it for you.
1. Low-pressure tire gauge
2. Owner
’s tool kit
3. Owner ’s manual
3
2
1
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EBU21743Periodic maintenance chart for the emission control system 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 *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 *Carburetor 
Check starter (choke) operation and correct if nec-
essary.
 Check engine idling speed and adjust if neces-
sary. √√√√
5 *Crankcase breather
system 
Check breather hose for cracks or other damage,
and replace if necessary. √√√
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6*Exhaust system 
Check for leakage and replace gasket(s) if neces-
sary.
 Check for looseness and tighten all screw clamps
and joints if necessary. √√√
7 Spark arrester Clean. √√√
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 4 Monday, June 13, 2011 2:57 PM

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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

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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

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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

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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

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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
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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